Environmental barrier coatings on alumina-reinforced CMCs: Experimental validation and numerical modeling of thermal stability

Abstract

Recent advancements in ceramic matrix composites (CMCs), including SiC/SiC, C/SiC, C/C, Al2O3 reinforced Al2O3, face various challenges at high temperature applications, including grain growth, sintering, and creep deformation which are leading to strength loss. The new generation of Environmental Barrier Coatings (EBCs) must allow the protection of these CMCs when operating under harsh conditions, which can reach up to 1100 °C in some applications, such as gas turbines and certain reforming processes. In this work, 8 wt% yttria stabilized zirconia (8YSZ) applied by Atmospheric Plasma Spraying (APS) on top of a porous alumina oxide matrix with reinforced alumina fibers Al2O3/Al2O3-CMC (OCMC), considering different interfaces, has been studied. Surface morphology and pre-treatment of CMCs is the most challenging part for thermal spray applications. Hence, two different surface structure were used in this work. The results show that the roughness of OCMC can be reduced from Rz = 41.8±6.8 μm to 20.3±1.1 μm with the new porous bond coat and plasma sprayed coating, resulting in a homogeneous surface morphology.. In terms of thermal stability, a numerical model that combines Object Oriented FEM (OOF) and Cohesive Zone Model CZM tools, has been developed to evaluate the effect of the porosity of the real microstructure and the characteristics of the interfacial roughness profile, respectively, in CMC/EBC structures. In addition, other materials, such as La2Zr2O7 and Y2O3, have been numerically studied in order to evaluate their suitability as EBC.