Integrated Microstructural and Chemical Approach for Improving CMAS Resistance in Thermal and Environmental Barrier Coatings

This study provides an investigation into the influence of surface roughness, porosity, and chemistry on the wettability and infiltration behavior of calcia-magnesia-alumino-silicates (CMASs) in thermal and environmental barrier coatings (T/EBCs) used in high-temperature gas turbine engines. High-temperature contact angle measurements were performed at 1260 °C on 7 wt.% yttria-stabilized zirconia (7YSZ) and yttrium ytterbium disilicate (YYbDS, (Y1/2Yb1/2)2Si2O7) to evaluate the interaction of CMASs with different surface finishes and coating microstructures. The findings demonstrate that porosity plays a dominant role in determining CMAS infiltration dynamics. In YYbDS, increasing porosity from 6.3% to 22.7% facilitated the formation of an apatite layer that limited CMAS penetration to approximately 2 µm. Surface roughness exhibited a subtler influence in that reducing Sa from 0.61 µm to 0.05 µm increased the change in the contact angle by ~2°, although its impact was found to be less significant compared to porosity and reactive chemistry. These results indicate that an integrated approach that optimizes porosity, chemistry, and surface morphology can significantly enhance CMAS resistance. The study emphasizes that leveraging both microstructural and chemical properties is critical to developing coatings capable of withstanding the harsh conditions encountered in aerospace environments.