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<p>In harsh service environments, the corrosion behavior of CaO-MgO-AlO<sub>1.5</sub>-SiO<sub>2</sub> (CMAS) on thermal barrier coatings is a primary factor contributing to failure. In this study, atmospheric plasma-sprayed 8&#xa0;wt.% yttria-stabilized zirconia coatings were glazed using a nanosecond laser operating in an ultra-high-frequency mode. By precisely controlling the single-pulse energy, laser melting was achieved on the coating surface. A smooth glazed layer (LGed) with sufficient thickness (21.5 ± 1.3&#xa0;μm) and narrow cracks (&lt; 1.30 ± 0.26&#xa0;μm) was formed under minimal heat-affected zones. CMAS sessile drop experiments were performed at 1250&#xa0;°C, and the results indicated that the LGed layer significantly suppressed CMAS spreading, degradation, and penetration. The reduction in surface capillary forces resulted in a 76% decrease in the CMAS spreading area (from 102.402 ± 3.722 to 24.465 ± 1.910 mm<sup>2</sup>), while the contact angle increased by 343% (from 2.8 ± 0.2° to 12.4 ± 0.5°). The increased surface density and decreased surface roughness effectively suppressed dissolution reactions, resulting in a 70% reduction in corrosion layer thickness (from 15.1 ± 0.5 to 4.5 ± 0.3&#xa0;µm). The presence of narrow cracks effectively limited CMAS penetration, preventing deposits and pore formation at the coating–substrate interface.</p>

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Enhanced CMAS Corrosion Resistance of APS 8YSZ Coatings via Ultra-High-Frequency Nanosecond Laser Glazing

  • 期刊论文

  • 发表日期：

    2026年2月9日

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  • Kun Huo,
  • Zhenqiang Liu,
  • Jianhui Bai,
  • Hun Guo,
  • Xiaofeng Zhang,
  • Jie Cai,
  • Fengze Dai

摘要

In harsh service environments, the corrosion behavior of CaO-MgO-AlO1.5-SiO2 (CMAS) on thermal barrier coatings is a primary factor contributing to failure. In this study, atmospheric plasma-sprayed 8 wt.% yttria-stabilized zirconia coatings were glazed using a nanosecond laser operating in an ultra-high-frequency mode. By precisely controlling the single-pulse energy, laser melting was achieved on the coating surface. A smooth glazed layer (LGed) with sufficient thickness (21.5 ± 1.3 μm) and narrow cracks (< 1.30 ± 0.26 μm) was formed under minimal heat-affected zones. CMAS sessile drop experiments were performed at 1250 °C, and the results indicated that the LGed layer significantly suppressed CMAS spreading, degradation, and penetration. The reduction in surface capillary forces resulted in a 76% decrease in the CMAS spreading area (from 102.402 ± 3.722 to 24.465 ± 1.910 mm2), while the contact angle increased by 343% (from 2.8 ± 0.2° to 12.4 ± 0.5°). The increased surface density and decreased surface roughness effectively suppressed dissolution reactions, resulting in a 70% reduction in corrosion layer thickness (from 15.1 ± 0.5 to 4.5 ± 0.3 µm). The presence of narrow cracks effectively limited CMAS penetration, preventing deposits and pore formation at the coating–substrate interface.