Extended Lifetime of Dual-Layer Yttria-Stabilized Zirconia APS/Gadolinium Zirconate SPS Thermal Barrier Coatings in Furnace Cycle Tests

Gadolinium zirconate (Gd2Zr2O7, GZO) has been investigated for two decades as a thermal barrier coating (TBC) material in gas turbines. The advantages of this material over conventional yttria-stabilized zirconia (YSZ) are its lower thermal conductivity, phase stability, and low sintering tendency at elevated temperatures above 1200 °C. However, a major disadvantage is the low fracture toughness of the material and the reaction with the thermally growing oxide layer (TGO). As a result, single-layer GZO coatings cannot be used as TBCs. To overcome these challenges, the present study focuses on the development of double-layer TBC systems, produced with a single gun to keep the manufacturing time low. The respective layers were optimized for specific requirements using a porous atmospheric plasma spray (APS)-YSZ interlayer covered by a suspension plasma sprayed (SPS)-GZO top layer. In furnace cycling tests at 1100 °C, the double-layer systems developed in this study were able to achieve a significant increase in thermal cycle life compared to single-layer APS-YSZ coatings. In addition, the failure mechanism after thermal cycling was investigated, and phase analysis was performed using XRD. The examination of Young’s modulus and the hardness of the layers revealed sintering in the GZO layer due to thermal cycling, while the APS layer showed only minor changes.