Synthesis and coating properties of (La0.5Eu0.25Y0.25)2Zr2O7 ceramic powder

The (La 0.5 Eu 0.25 Y 0.25 ) 2 Zr 2 O 7 (LEYZ) ceramic powder for spraying was prepared and synthesised by combining spray granulation and solid phase reaction phase, and a double ceramic layer structure with (La 0.5 Eu 0.25 Y 0.25 ) 2 Zr 2 O 7 ceramic surface coating and YSZ intermediate coating was prepared by atmospheric plasma spraying. Experimental characterisation revealed that the moulding state of spray granulated powders was significantly influenced by the solid content. When the solid content is small, the viscosity of the slurry is insufficient, and the prepared powder has poor formability and small overall particle size. When the solid content is large, the slurry is too viscous, which easily leads to unfavourable conditions such as sticky walls. The best formability of the pelletised powder was obtained with a solid content of 55 wt-% and a binder content of 2.0 wt-%. Compared with La 2 Zr 2 O 7 (LZ) ceramics, the fracture toughness of the rare-earth co-doped modified LEYZ ceramic coating was increased by 8.4% and the bond strength was increased by 49.9%, showing good toughness and crack resistance. Moreover, LEYZ coating has significantly better resistance to solid phase particle erosion than LZ coating, with 46.3% and 45.4% reduction in erosion rate at 45° and 90°, respectively.