Growth Of Oxide Layer Research Articles

Growth of Surface Oxide Layers on Dendritic Cu Particles by Wet Treatment and Enhancement of Sinter-Bondability by Using Cu Paste Containing the Particles

Pastes were prepared using dendritic Cu particles as fillers, and a compression die attachment process was implemented to establish a pure Cu joint using low-cost materials and high-speed sinter bonding. We aimed to grow an oxidation layer on the particle surface to improve sinter-bondability. Because the growth of the oxidation layer by general thermal oxidation methods makes it difficult to use as a filler owing to agglomeration between particles, we induced oxidation growth by wet surface treatment. Consequently, when the oxidation layer was appropriately grown by surface treatment using an acetic acid–ethanol solution, we obtained an improved joint strength, approximately 2.8 times higher than the existing excellent result based on a bonding time of 10 s. The joint formed in just 10 s at 300 °C in the air under 10 MPa compression showed a shear strength of 28.4 MPa. When the bonding time was increased to 60 s, the joint exhibited a higher strength (35.1 MPa) and a very dense microstructure without voids. These results were attributed to the acceleration of sintering by the in situ formation of more Cu nanoparticles, which effectively reduced the increased oxide layers in the particles using a reducing solvent.

Characterization of thin oxide layers formed by Ti-Nb Alloy anodization

Ti-Nb alloys are gaining more prominence in the industrial and scientific environment due to their high biocompatibility, mechanical strength/weight ratio, and exceptional corrosion resistance compared to other metallic materials. Metals exhibiting this passivation characteristic are known as metal valves and may exhibit semiconductive or insulating oxides. Controlling the growth of distinct thickness layer films is possible through tunning anodization conditions. In this work, a Ti-Nb binary system is anodized, and the grown oxide layer is comprehensively characterized using ellipsometry based on its optical properties and thickness at different applied potentials. Confocal Microscopy assessed their surface roughness, and SEM/EDS probed the surface material's elemental composition. CF-LIBS successfully confirmed the 70/30 composition of the Ti-Nb alloy. Raman spectra have detected the presence of amorphous TiO2 and Nb2O5 at potentials higher than 80V, 100V, and 120V. Finally, a linear dependence of the oxide thickness with the applied potential was observed.

Discerning the effect of various irradiation modes on the corrosion of Zircaloy-4

Using proton irradiation, this study investigates the individual influence of several factors on the corrosion kinetics of Zircaloy-4 in a hydrogenated water environment simulating a Pressurized Water Reactor (PWR). Using both simultaneous irradiation-corrosion and autoclave corrosion, we separately examine (i) the effect of pre-irradiation on modifying the structure of the material, (ii) the impact of irradiation on creating defects in the growing oxide layer during corrosion, and (iii) the influence of irradiation on increasing the corrosion potential through radiolysis during corrosion. To replicate the neutron-irradiated microstructure, two proton pre-irradiation schedules were employed: Schedule 1 (isothermal irradiation at 350°C to 5 dpa) to simulate high-temperature PWR conditions, and Schedule 2 (two-step process: irradiation to 2.5 dpa at -10°C followed by 2.5 dpa at 350°C) to simulate lower temperature PWR and Boiling Water Reactor (BWR) conditions. Long-term autoclave corrosion testing for 360 days at 320°C revealed no significant difference between unirradiated samples and those pre-irradiated according to either schedule, with all samples exhibiting sub-cubic kinetics within the pre-transition regime. Pre-irradiated samples underwent Simultaneous Irradiation Corrosion (SIC) tests, corroding in 320°C water while being irradiated with protons. Corrosion was found to accelerate in all SIC-tested samples relative to autoclave conditions, with the greatest increase observed in non-pre-irradiated regions of the samples. Pre-irradiation with either schedule resulted in a slower corrosion rate compared to non-pre-irradiated regions under SIC conditions. The degree of radiolysis observed in the SIC tests surpassed typical PWR conditions, approaching levels found in BWRs. Radiolysis products were identified as a primary contributors to accelerated corrosion, corroborated by radiolysis bar tests. These findings underscore the intricate interactions between irradiation, corrosion, and water chemistry in determining Zircaloy-4 corrosion kinetics within nuclear reactor environments.

Additive manufactured ODS-FeCrAl steel achieves high corrosion resistance in lead-bismuth eutectic (LBE)

Developing corrosion resistant alloys used in lead-bismuth eutectic (LBE) is essential for lead-cooled fast reactors (LFRs). In this work, additive manufacturing was applied to fabricate oxide dispersion-strengthened FeCrAl steels (ODS and Y-ODS), and the latter contains 1.5 wt.% Y2O3 nanoparticles. After exposure in LBE at 450 °C for 1000 hours, both alloys generate a compact, uniform and stable Cr2O3/Al2O3 protective oxide layer (below 200 nm). Benefits from the quick transient oxidation rate at the initial stage, the oxide layer realizes a slow oxidation kinetics and achieves high corrosion resistance to LBE attack. More importantly, the addition of Y2O3 induce the formation of Y-Al-O-type oxide nanoparticles which provides an additional source of Al3+ at the interface and promotes the growth of an internal oxide layer within Al2O3, and thus subsequently the oxides layer demonstrates remarkable stability. This study highlights the potential application of additive manufacturing in advanced materials for LFRs.

3D digital holography for measuring particle impact crater morphology and in-situ analysis of oxidation healing on steel surfaces

Deformation and erosion of steel due to particle impacts in high-temperature environments are common issues in industrial applications. Under high-temperature conditions, an oxide layer forms that affects the deformation and erosion of the steel surface following particle impacts. Studying the interaction mechanism of oxidation and deformation (erosion) is of considerable significance. Traditional research methods primarily involve ex-situ measurements on samples post-erosion and oxidation, which cannot capture the morphological changes of the steel surface immediately following particle impact. Utilizing 3D digital holography (DH) technology, this paper develops a measurement system to investigate the surface morphological changes in steel induced by single particle impacts. We utilized this experimental system to measure the impact crater morphology of 500 μm zirconia particles impacting Q690 steel sheets. Our findings indicate that Hertzian ring cracks formation is significantly affected by heating temperature and impact angle. Notably, oxide layer peeling and erosion occurred at an impact angle of 30°. Additionally, impact crater depths at a 90° angle and impact speeds ranging from 1 to 20 m/s varied between 0.66 and 4.25 μm, with crater depths showing a correlation to the thickness of the oxide layer. Concurrently, in-situ measurements of the impact crater healing process during heating revealed that the crater formed at a 30° impact angle, which had numerous microcracks, exhibited significantly better healing compared to the crater formed at a 90° impact angle. The thickening process of the oxide layer were also analyzed, leading to the derivation of the oxide layer growth kinetic equation based on the measurement data: . This study is the first to use DH technology to measure the surface morphology of steel and to conduct in-situ analysis of the oxide layer thickening process following particle impact and during heating. This approach provides a novel perspective for understanding the erosion-oxidation interaction mechanism.

Effect of Zr addition on the corrosion resistance of Ti-Mo alloy in the H2O2-containing inflammatory environment

Reactive oxygen species (ROS), produced by immune cells during inflammatory reaction, are known to promote corrosion of standard biomedical materials such as CP-Ti and Ti-6Al-4V. Electrochemical corrosion in the ROS environment can be further accelerated in the vicinity of fretting regions, where titanium can be polarized towards negative potentials. This study considers both of these aspects and presents corrosion analysis under complex inflammatory conditions for Ti-Mo and Ti-Mo-Zr alloys, which offer exceptional strain-hardening behavior and ductility. Combining electrochemical impedance spectroscopy (EIS) and atomic emission spectroelectrochemistry (AESEC) allowed us to understand the origin of ROS-induced corrosion. At free corrosion conditions, Zr was found to suppress oxide layer growth without any significant effect on the dissolution process. On the other hand, Zr suppressed dissolution rate under cathodic potentials. Although applying cathodic potential resulted in a rapid increase of dissolution rate, cross-section transmission electron microscopy (TEM) analysis did not reveal significant influence of the short cathodic polarization on the oxide film growth during further prolonged exposure at free corrosion conditions.

A grey relational analysis of the micro arc oxidation process parameters and their effects on Ti-6Al-7Nb coating performance and corrosion resistance for biomedical uses

Abstract In current investigation micro arc oxidation of Ti6Al7Nb alloy was done to improve its surface properties and corrosion resistance. Mixture of Na2SiO3, Na3PO412H2O and KOH is used as electrolyte. MAO treated Ti6Al7Nb specimens were examined using x-ray diffraction (XRD), energy dispersive spectroscopy (EDS) and scanning electron microscopy (SEM) to examine their morphology and phase composition. It was observed that electrolyte composition is simultaneously included in the growing oxide layer during MAO process. From electrochemical study it was found that corrosion resistance of the Ti6Al7Nb increases during EIS testing in 0.9% NaCl solution. It was found that frequency, duty cycle, current and processing time effect the surface roughness, thickness, hardness and corrosion resistance of coating. Out of above mention parameters frequency and duty cycle has major impact on performance parameters. The objective of current investigation is to find out effects MAO process parameters on coating performance parameters such as coating thickness, hardness, surface roughness and corrosion resistance. At duty cycle of 50%, frequency 500 Hz, current 300 mA and processing duration 7.5 min, highest coating thickness 32.96 μm and surface roughness 3.3680 μm was obtained. Process parameters have the influence on pore size, biggest average pore size 3.8519 μm was obtained at duty cycle of 50%, frequency 500 Hz, current 300 mA and processing duration 7.5 min. Grey relational analysis is done to determine which process variable has the most influence on performance parameters. From grey relational analysis technique, it was observed that duty cycle 50%, frequency 500 Hz, current 300 mA, and processing time 7.5 min are ideal process parameters for higher coating thickness, hardness, surface roughness and better corrosion resistance. From grey relation analysis it was also found that frequency has most significant impact on performance parameters after that duty cycle, then current and at last processing time.

Effect of irradiation on the corrosion of 304 stainless steel in pressurized water reactor (PWR) simulated water chemistry

In this study, the corrosion behavior of pre-ion-irradiated 304 SS is compared to that of un-irradiated 304 SS in simulated Pressurized Water Reactor (PWR) conditions for both early stages of corrosion and longer exposure times. Transmission electron microscopy is used to characterize the oxide scale. The study shows that although the pre-irradiated microstructure does not change the nature of the oxide and its dual-layer structure (i.e. inner/outer oxide layers) formed on 304 SS, the path of growth of the inner oxide layer is affected by the irradiated microstructure resulting in oxide protrusions into the matrix; a mechanism is proposed.

Local high temperature phenomena near the complex interfaces of thermal barrier coatings based on non-Fourier model

Thermal barrier coatings (TBCs) consist of a metal substrate (Sub), a bond coat (BC), and a ceramic top coat (TC). The ceramic coating is a porous dielectric layer with a significant relaxation time that cannot be ignored. In high-temperature environments, an irregularly shaped thermally grown oxide layer (TGO) forms between the BC and the TC. Therefore, using non-Fourier model to describe the thermal contact process of TBCs with complex interface can get more accurate results. However, it is difficult to obtain the analytical solution of this model. This paper introduces a finite volume method based on unstructured meshes to address the non-Fourier heat transfer process in the complex interfaces of multilayer TBCs. The gradient reconstruction technique is employed to calculate the cell derivatives on the surface. The method's reliability is confirmed through a comparison with a two-dimensional analytical solution. The results indicate that the thermal wave travels at a limited speed within the TC layer. After passing through the interface, the thermal wave travels very fast within the BC and Sub layers, due to the influence of thermal wave reflection and superposition, obvious local high temperature will be formed near the interface. In addition, the effects of thermal conductivity, relaxation time and interface shapes on the non-Fourier heat conduction process of TBCs are also discussed. The results of this paper are useful for the structural design and failure mechanism research in TBCs.

Corrosion kinetics and mechanisms of 15–15Ti steel in flowing liquid lead-bismuth eutectic at 500°C

The application of Liquid Lead-Bismuth Eutectic (LBE) as a coolant in Lead-cooled Fast Reactors (LFRs) presents significant challenges due to its corrosive nature, especially at elevated temperatures. This study investigates the corrosion kinetics and mechanisms of 15–15Ti stainless steel in flowing LBE at 500 °C with oxygen concentrations ranging from 1 to 3 × 10−6 wt% and a flow rate of 1 m s-1. The research highlights the formation and growth of the Fe-Cr spinel oxide layer, which follows a parabolic rate law indicative of a diffusion-controlled process, crucial for long-term material stability predictions. Despite the initial effectiveness of the Fe-Cr spinel layer in mitigating corrosion, its integrity is compromised over time due to spallation and dissolution, allowing penetration of LBE elements and selective dissolution of Fe, Ni, and Cr. The study reveals a complex interplay between direct dissolution of steel components and spallation of the oxide layer, providing critical insights into material loss mechanisms and the degradation of structural materials in LBE-cooled reactors.

Enhancing bonding strength between Cu and Cu2O through crystallographic orientation variation

Copper is a widely used material but is susceptible to oxidation under atmospheric conditions, resulting in the formation of oxide layers that are prone to cracking and peeling even under minimal mechanical stress. To address this issue, the development of a dense and solid copper oxide layer with strong oxide–copper interfacial bonding is crucial; however, achieving such strong bonding is challenging owing to the substantial lattice misfit of approximately 18 %. This study presents a novel approach to create an adhesive and robust Cu2O layer on copper through a simple and reproducible heat treatment procedure conducted under extremely low air pressures in vacuum conditions. Remarkably, an unexpected reduction in lattice misfit at the interface is achieved by promoting the growth of a large-grain oxide layer that fully covers the copper surface. Despite the presence of arbitrary crystallographic relationships between copper and Cu2O, the crystallographic orientation of copper is intentionally altered by introducing geometrically necessary dislocations and atomic array tilting, which results in the formation of a stable oxide layer that exhibits exceptional resistance against cracking, peeling, plastic deformation, and mechanical scratching. The effectiveness of this approach is demonstrated by the enhanced robustness and stability it imparts to copper oxides.

Comparison of diffusion coatings resistance on ferritic and austenitic-stainless steels at 650 °C in steam oxidation

Iron-aluminide coatings were deposited on T24, P92 and Incoloy 800HT (IN-800HT) by pack-cementation and by a water-based slurry. According to the differences in heat treatments between the two processes, Al-rich phases, i.e. Fe4Al13 and Fe2Al5 were obtained by pack cementation and only B2-(Fe, Ni)Al by slurry. Vertical or horizontal cracks were present on certain coatings, the former being due to the coefficient of thermal expansion (CTE) mismatch with the substrate while the latter were related to the brittleness of the Al-rich phases. The oxidation behaviour of uncoated and coated substrates was studied at 650 °C up to 1000 h under a low steam flow rate (1.07 × 10−5 m/s). The aluminide coatings were very protective on the low Cr substrates (i.e. T24 and P92) because of the formation of a very thin oxide scale compared to the non-protective thick layers of Fe3O4 and Fe2O3 that grew on both uncoated substrates. In contrast, none of the coatings significantly improved the oxidation resistance of the IN-800HT steel despite the growth of a thin oxide layer made of (Fe, Cr)2O3 and (Fe, Cr)3O4 at 650 °C.

Formation of Ca, P, and Zn-doped ZrO2/TiO2 coating layer via plasma electrolytic oxidation and magnetic sputtering: Improving surface characteristics and biocompatibility of Ti–6Al–4V alloy

The study demonstrated the Ca, P, and Zn-doped ZrO2/TiO2 coating layer via plasma electrolytic oxidation (PEO) and radiofrequency magnetron sputtering (RF-MS) for improving surface characteristics and biocompatibility of Ti–6Al–4V alloy. The process involved sandblasting (SB) to create micro-scale irregularities on the alloy surface, followed by RF-MS and PEO. The coating's morphology, elemental composition, phase composition, and chemical analysis were examined by FE-SEM with energy-dispersive spectroscopy, X-ray diffraction, X-ray photoelectron spectroscopy, and Raman analysis. The dual surface treatment resulted in the formation of composite coatings with TiO2, ZnO, ZrO2, and HA presence and displayed anisotropic multi-scale porous morphology while the surface texturing created by the SB process facilitated mechanical interlocking during the oxide layer growth. In the SB-Zr + PEO-Zn sample, the phase analysis indicated the strain-induced stabilization of t-ZrO2 in the PEO coating layer due to the incorporation of Ca2+ ions, and the formation of zinc-substituted hydroxyapatite was observed that showed enhanced roughness and wettability. Also, reduced hardness and elastic modulus (comparable to that of cortical bone) were observed due to transformation toughening under stress from t-ZrO2 to m-ZrO2. The presence of TiO2, ZrO2, ZnO, and HA within the coating, all act as protective barriers in effectively reducing corrosion rates. The biological analysis demonstrated better biocompatibility, including promoting cell proliferation, cell adhesion, osteoblast differentiation, ALP activity, and mRNA expression of several osteogenic markers of the cells cultured on the SB-Zr + PEO-Zn sample. These results demonstrated the higher potential of the PEO coating system with higher biocompatibility and osseointegration ability for dental implants.

Effect of long-term thermal aging on lead-bismuth eutectic corrosion behavior of 9Cr ferritic/martensitic steel

In lead-cooled fast reactor (LFR) systems, the liquid lead-bismuth eutectic (LBE) coolant provides a corrosive environment that damages the steel components during high-temperature operation. This study investigated the microstructural deterioration of 9Cr ferritic/martensitic (F/M) steel under thermal aging at 550 °C for 2,000, 10,000, or 20,000 h and its effect on oxidation corrosion in an LBE environment using multiscale characterization techniques. The results indicated that the thickness of the internal oxidation zone (IOZ) increased significantly with extended thermal aging, whereas that of the spinel layer remained relatively constant. The abundant subgrain boundaries that emerged during extensive thermal aging facilitated Fe diffusion, and the enlarged Cr-rich M23C6 carbides contributed to the formation of preferential oxidation regions, accelerating IOZ layer growth. The spinel layer formed from the IOZ was influenced by microstructural defects within the IOZ. A theoretical model describing the accelerated oxide layer growth due to thermal aging was developed. These findings support the advancement of LFR technology.

Evaluation of influence of dissolved oxygen on corrosion behaviors of FeCrW model alloys in 360 °C water

The dissolved oxygen in a coolant can affect the oxidation properties of structural materials. A desirable oxide phase formation is achieved by manipulating the oxygen level in the coolant, which can mitigate structural material degradation in nuclear power plants. Therefore, the role of dissolved oxygen in the corrosion of structural materials in aqueous environments needs to be understood. In this study, a short-term corrosion test (up to 300 h) of Ferritic/Martensitic steels (F/M steels; FeCrW model alloys), namely, Fe12Cr1W, Fe9Cr1W, and Fe9Cr, in stagnant water at 360 °C was performed in a pressurized autoclave with the dissolved oxygen concentration controlled to 1 ppm or a very low level (<1 ppm). The results of the corrosion tests showed that an increase in the oxygen level in the water elevated the corrosion potential, allowing the phase transition of iron oxide from magnetite (Fe3O4) to hematite (Fe2O3), whereas there was no significant correlation between the concentrations of the alloying elements Cr and W and the oxide growth rate. In addition, hematite was found to mitigate further oxide growth. Finally, a mechanism for the growth of the initial oxide layer was proposed based on the experimental results.

Micro-arc and thermal oxidized titanium matrix composites for tribocorrosion-resistant biomedical implants

Superior tribocorrosion resistance is offered by titanium matrix composites (TMCs) compared to their unreinforced matrix metal, but bioactivity concerns are raised for biomedical applications. Simple methods such as micro-arc oxidation (MAO) and thermal oxidation (TO) are employed to enhance the bioactivity and degradation resistance of Ti. However, the impact of those surface treatments on TMC surfaces is poorly understood. Therefore, the present work aimed to explore the influence of MAO and TO treatments on the surfaces of in-situ Ti-TiB-TiC and ex-situ Ti-B4C composites, and to assess their corrosion and tribocorrosion performance. Corrosion and tribocorrosion tests were conducted in phosphate-buffered saline solution (PBS) at body temperature. Electrochemical assays were performed by means of potentiodynamic polarization scans while additional potentiostatic tests were performed for the untreated ex-situ composites. Tribo-electrochemical assays were conducted under open circuit potential (OCP) and under normal loads of 0.5 and 10 N against a 10 mm diameter alumina ball in a reciprocating ball-on-plate tribometer. Results revealed reinforcement detachments in ex-situ composites after both treatments. This was primarily attributed to oxide layer growth at the reinforcement/reaction zone interface. Hence, the use of MAO and TO on ex-situ Ti-B4C composites may not be appropriate for biomedical applications, mainly because the B4C particles tend to detach during the treatment. In contrast, TO-treated in-situ composites displayed excellent combination of corrosion and tribocorrosion performance, even under elevated applied loads, mainly due to the existence of the oxygen diffusion zone (ODZ) beneath the oxide surface produced by TO, together with the more stable electrochemical properties observed during steady-state conditions.

Structural evolution and enhanced thermal cycling life of HVAF-sprayed NiCrAlY bond coat modified by YSZ

Thermal barrier coatings with varied bond coat structures were deposited using high-velocity air fuel spraying. Highly hard YSZ particles are introduced into the NiCrAlY bond layer by accelerating to supersonic speeds at low temperatures to change the porous structure of the bond coat. We systematically increased the YSZ content in NiCrAlY bond coats and extensively investigated microstructure, oxidation behavior, thermal cycling life, and residual stress variation of the bond coats suing a combination of scanning electron microscopy, optical microscope, confocal Raman microprobe. Introduction of YSZ particles reduced the porosity of NiCrAlY bond coat from 2.69% to 0.45%, and altered the oxidation behavior of the bond layer. The NiCrAlY mixed YSZ composite structure induced the formation of a complex and thin thermal growth oxide layer on the bond coat during oxidation process, greatly alleviating and reducing the thermal stress generated of the coating and during the thermal cycling test. And the thermal cycling life of the NiCrAlY mixed YSZ composite structure coating is 2.8 times longer than that of the ordinary NiCrAlY coating. This finding highlights the significance of the bond coat structure in enhancing the service life of thermal barrier coatings.

Experimental study of a thin thermally grown oxide layer in thermal barrier coatings based on the SWT-BP algorithm and terahertz technology

As a promising nondestructive testing (NDT) technique with a very adaptive physical modeling of wave transmission process, terahertz technology is used for the detection and characterization of nonpolar materials and the evaluation of layered and/or defective structures. THz-TDS can also be used to perform spectroscopic analysis and detect structural defects in thermal barrier coatings (TBCs) of aero-engines. Although it is generally difficult to measure the structure of the thin oxide layer of the thermal barrier coatings whose thickness is generally lower than 30 µm (the current axial resolution of the THz-TDS cannot exceed 30 µm). We were able to complete the detection of the oxide layer within 1–29 µm through simulation by using the SWT-BP algorithm. In this study, the analysis was performed on real-world samples, the fitting degree of the SWT-BP algorithm reached 0.77, and the minimum prediction error was less than 0.1 µm. The paper also put forward some improvement measures about the experimental results.

On the Interaction between PEDOT:PSS Dispersions and Aluminium Electrodes for Solid State Electrolytic Capacitors

The use of conductive polymers in aluminium electrolytic capacitors prevents leakage and enlarges the temperature use range when compared with their liquid counterparts. PEDOT:PSS is an outstanding candidate due to its tunable properties, i.e., electronic conductivity (10−5 to 103 S/cm), and its high thermal stability. As a result of their synthesis, PEDOT:PSS dispersions are characterized by a low pH value, which can influence pH sensitive materials such as aluminium. However, no work to date has studied the interaction between PEDOT:PSS dispersions and aluminium oxide substrates. In this work, the interface and interaction between PEDOT:PSS and an aluminium electrode were studied for the first time via odd random phase electrochemical impedance spectroscopy and analysed post mortem by SEM and AFM characterization. PEDOT:PSS dispersions at different pH values (1.9, 4.9, 5.8) were applied in a layered manner onto a non-etched aluminium substrate with a grown oxide layer on top, which provided a model system for the analysis of the interface. The analysis showed that the acidic PEDOT:PSS dispersions attacked the aluminium substrate, forming pores on the surface, but had a positive impact on the capacitance of the aluminium oxide/PEDOT:PSS systems. On the other hand, neutral dispersions did not affect the aluminium electrode, but showed poor layer formation properties, and the electrochemical analysis displayed a dispersion of results ranging from capacitive to resistive behaviour.

Thermal shock resistance of a novel (Gd1/6Tb1/6Dy1/6Tm1/6Yb1/6Lu1/6)2Si2O7 environmental barrier coating

AbstractMulticomponent rare earth (RE) disilicates have been recognized as promising candidates for environmental barrier coatings (EBCs). In this work, a novel EBC system with (Gd1/6Tb1/6Dy1/6Tm1/6Yb1/6Lu1/6)2Si2O7 as top coat and Si as bond coat was deposited on SiC‐based substrates by atmospheric plasma spraying technology and subjected to 200 thermal shock cycles at 1350°C. The composition and microstructure evolution in the coating during thermal cycling were investigated using x‐ray diffraction analysis and scanning electron microscopy. The results show that the as‐prepared EBC remains dense and integrated, and no obvious spalling or penetrating cracks could be observed in the coating after 200 thermal shock cycles. Furthermore, the average thickness of thermal growth oxide layer between (6RE1/6)2Si2O7 top coat and Si bond coat is 0.71 ± 0.17 µm and 0.98 ± 0.23 µm before and after the thermal cycling, respectively, indicating the excellent thermal shock resistance of (6RE1/6)2Si2O7 EBC. The present study presents a novel EBC with excellent thermal shock ability and is expected to contribute to the development of EBC for advanced SiCf/SiC ceramic matrix composites.