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In this work, the NiCrAlY bond coat was produced as an intermediate layer by the APS approach, and the nanostructured Gd2Zr2O7 was deposited by electron beam-physical vapour deposition (EB-PVD) on Nimonic 80A superalloy substrate. The effect of the deposition technique on the microstructure and surface topography of the coatings was studied. A uniform layer of coatings without pores and cracks was achieved with an average roughness (Ra) of 52.599 nm. The cross-sectional scanning electron microscopy (SEM) images show that the coatings developed comprise of leafy structure with a porosity of 4.57%, validating the dense microstructure of the TBCs. The base material, bond coat, and GZ coatings were further subjected to high-temperature hot corrosion (HTHC) studies under Na2SO4 + 55% V2O5 corrosive salt mixture environment at 850 °C for 8 h. The substrate and bond coat had severe spallation along with higher weight gain. However, the GZ coatings surface was intact with corrosive products without any spallation of the coating layer accompanied by minimal weight gain protecting the sublayers of the TBC system.

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Microstructural Evaluation of Gd2Zr2O7 Thermal Barrier Coating Developed by EB-PVD Technique

  • 会议论文

  • 发表日期：

    2026年

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  • P. Hariharan,
  • Ganesan Bhavesh,
  • Durgalakshmi Dhinasekaran

摘要

In this work, the NiCrAlY bond coat was produced as an intermediate layer by the APS approach, and the nanostructured Gd2Zr2O7 was deposited by electron beam-physical vapour deposition (EB-PVD) on Nimonic 80A superalloy substrate. The effect of the deposition technique on the microstructure and surface topography of the coatings was studied. A uniform layer of coatings without pores and cracks was achieved with an average roughness (Ra) of 52.599 nm. The cross-sectional scanning electron microscopy (SEM) images show that the coatings developed comprise of leafy structure with a porosity of 4.57%, validating the dense microstructure of the TBCs. The base material, bond coat, and GZ coatings were further subjected to high-temperature hot corrosion (HTHC) studies under Na2SO4 + 55% V2O5 corrosive salt mixture environment at 850 °C for 8 h. The substrate and bond coat had severe spallation along with higher weight gain. However, the GZ coatings surface was intact with corrosive products without any spallation of the coating layer accompanied by minimal weight gain protecting the sublayers of the TBC system.