Alumina scale growth at zirconia-MCrAlY interface: a microstructural study

Abstract

High-temperature oxide scale growth at the ceramic-metal interface is a major contributor to the thermomechanical resistance of thermal barrier coatings for hot stages of gas turbines. In order to better understand this phenomenon, microstructural observations of the alumina scales formed at 1100 and 1200 °C under air, between low-pressure plasma-sprayed NiCrAlY and air plasma-sprayed ZrO2-8.5 wt % Y2O3, have been performed by classical and analytical transmission electron microscopy on transverse thin foil specimens. The evolution of the oxide grain morphology from the metal-oxide to the oxide-oxide interface suggests that the scale growth principally takes place at the metal-oxide interface. Segregation of yttrium at oxide grain boundaries has been detected as well as significant quantities of zirconium inside the alumina grains. The oxide growth seems to be dominated by a classical grain-boundary oxygen diffusion mechanism. The presence of zirconium inside the alumina grains also suggests that Al2O3 partially forms by chemical reduction of ZrO2 by AI. The comparison between the microstructures observed and that of alumina scales grown under similar conditions on bare MCrAlY alloys gives some insight into how the ceramic top-coat modifies NiCrAlY high-temperature oxidation mechanisms.