Improving the CMAS corrosion resistance of Gd2Zr2O7 TBCs via laser simultaneously induced texture/featherlike/dense structures

CaO–MgO–Al2O3–SiO2 (CMAS) deposits are one of the primary causes for the failure of thermal barrier coatings (TBCs). In this study, a texture/featherlike/dense composite structure was innovatively designed and prepared in situ on the surface of Gd2Zr2O7 (GZO) coatings via laser modification, to improve the CMAS corrosion resistance of TBCs. Phase field stimulation was employed to analyze the required laser power range for the formation of featherlike structures. The surface of the GZO coating was experimentally controlled to a textured structure with an increase in the wetting angle to the molten CMAS at 1250 °C from 102° (as-sprayed) to 126° (laser-modified). The cross-section of the laser-modified coating exhibited a featherlike structure measuring 18 μm, which is known for excellent strain tolerance. Furthermore, a dense coating of approximately 50 μm formed simultaneously under the featherlike layer, which effectively slowed the infiltration of the molten CMAS. After CMAS corrosion at 1250 °C for 1, 4, and 10 h, the unmodified GZO coating had a corrosion depth 2 times greater than the corrosion depth of the modified GZO coating. This study offers a solution for the preparation of featherlike structured ceramic coatings without the need for expensive vacuum equipment, such as EB-PVD and PS-PVD.