Abstract
Thermal barrier coatings (TBCs) prepared by plasma spray-physical vapor deposition (PS-PVD) applied in marine environments encounter a critical challenge of corrosion-induced failure. In this paper, yttria-stabilized zirconia (YSZ) TBCs with different microstructures were prepared via PS-PVD by varying powder feeding rates to investigate the influence of microstructural modifications on corrosion resistance. The effects of structural gradient, initial deposition mechanism, and pore distribution on corrosion resistance were explored. Additionally, the inhibition mechanisms of capillary effect and chemical reaction on molten salt penetration were confirmed. Finally, a microstructure gradient strategy for PS-PVD TBCs was proposed. The structurally graded TBCs tailored using this strategy exhibited excellent corrosion resistance, with the molten salt corrosion resistance surpassing that of conventionally processed PS-PVD TBC by over 50 %. These outcomes highlight the promising potential of the microstructure gradient strategy for enhancing the corrosion resistance of PS-PVD TBCs.
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