Abstract
Polymer-derived ceramic (PDC) coatings of considerable thickness can offer promising protection for metallic and superalloy substrates against oxidation and corrosion, yet the preparation remains challenging. Here, a SiOC/Al2O3/YSZ coating was prepared on a nickel alloy with a spraying method using Al2O3 and yttria-stabilized zirconia (YSZ) as passive fillers. The thickness can reach up to 97 μm with the optimal mass fraction and particle sizes of the passive fillers. A small or isolated SiOC phase is formed in the coating, which can effectively alleviate the shrinkage and cracking during the pyrolysis. The SiOC/Al2O3/YSZ coating exhibits low thermal conductivity and high bonding strength with the substrate. Moreover, the coating shows good thermal shock resistance between 800 °C-room temperature cycles and oxidation resistance at 1000 °C for 36 h. This work provides an effective guide for the design of thick PDC coatings to further promote their application in the thermal protective field.
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