Comparison of calcium–magnesium-alumina-silicate (CMAS) resistance behavior of produced with electron beam physical vapor deposition (EB-PVD) method YSZ and Gd2Zr2O7/YSZ thermal barrier coatings systems

Thermal Barrier Coatings (TBCs) are generally used in both industrial gas turbines and aircraft engines. In this study, metal powders with CoNiCrAlY content were coated on Inconel 718 nickel-based superalloy substrate materials using the cold gas dynamic spray (CGDS) method, which is a new generation thermal spray coating method. As a top coating, YSZ and Gd 2 Zr 2 O 7 /YSZ (GZO/YSZ), respectively, single and double layer ceramic layers were deposited with an innovative method, physical vapor deposition by electron beam (EB-PVD). All produced TBC systems were sprinkled with vermiculite powder containing CMAS minerals and subjected to CMAS corrosion tests and the effect of CMAS damage on the phase stability and microstructure of TBC systems was determined using elemental mapping analysis, X-ray diffraction (XRD) analysis, and scanning electron microscope (SEM). According to the results obtained, it has been determined that the double layer TBC system with GZO/YSZ is more resistant to CMAS damage than the single layer YSZ system. • This study purposes to investigate CMAS behavior of traditional single and double layer TBC systems. • Double layer Gd 2 Zr 2 O 7 /YSZ and Single YSZ EB-PVD TBCs were successfully coated on CoNiCrAlY metallic bond coats produced by cold spray dynamic spraying. • Changes of TGO layer, chemical compatibilities and microstructural properties of TBCs were comparatively investigated as functions of time and temperature. • Double layer Gd 2 Zr 2 O 7 /YSZ TBCs exhibit superior properties as compared to traditional single layered YSZ TBC.