Abstract
Sm2Zr2O7 and (Sm2/3Yb1/3)2Zr2O7 feedstocks prepared by spray drying have been used to produce ceramic thermal barrier coatings. Double-ceramic-layer thermal barrier coatings with an under-layer of 8 wt.% yttria-stabilized zirconia (YSZ) and a top-layer of Sm2Zr2O7 or (Sm2/3Yb1/3)2Zr2O7 were deposited by plasma spraying. Plasma sprayed Sm2Zr2O7 coatings are composed of a pyrochlore-type phase and a t-ZrO2 phase, while (Sm2/3Yb1/3)2Zr2O7 coatings exhibit a defect fluorite-type structure. The number of thermal shock failure at 1250 °C is 52 and 33 for Sm2Zr2O7/YSZ and (Sm2/3Yb1/3)2Zr2O7/YSZ coatings, respectively. The thermal shock failure of zirconates/YSZ double-ceramic-layer coatings mainly occurs inside ceramic layers, and is not caused by the thermal grown oxide layer from the bond coat.
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