Synthesis and performance of mullite/Y2Si2O7/ZrO2 coating: Microstructure, phase evolution, and thermal shock behavior

IF 3.5 3区材料科学 Q1 MATERIALS SCIENCE, CERAMICS Journal of the American Ceramic Society Pub Date : 2024-12-23 DOI:10.1111/jace.20342

Yongqiang Chen, Mao Chen, Beibei Tang, Guoqi Liu, Hongxia Li, Hailong Wang, Bingbing Fan

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Abstract

A uniform, dense, and well-bonded mullite/Y₂Si₂O₇/ZrO₂(MYZ) composite barrier coating was synthesized using a spraying technique followed by a two-step sintering process. The microstructure, phase composition, and thermal shock resistance of the MYZ coating were systematically investigated. The sintering process comprised two stages. In the initial stage (25–1350°C), granular mullite grains transformed into columnar crystals with progressive growth. Concurrently, a eutectic composite of mullite and Y₂Si₂O₇ formed and dispersed within the grain boundaries, significantly enhancing the coating's density and adhesion. In the subsequent stage (∼1400°C), ZrO₂ reacted with the eutectic composite to produce yttria-stabilized zirconia (YSZ) in situ. The YSZ phase exhibited excellent interfacial compatibility with the substrate, markedly improving the coating's high-temperature stability. As a result, the coating achieved high hardness and a coefficient of thermal expansion matching that of the SiC substrate. Remarkably, the MYZ coating withstood 20 thermal cycles between 25°C and 1200°C without noticeable interfacial damage.

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采用喷涂技术和两步烧结工艺合成了一种均匀、致密、结合良好的莫来石/Y2Si2O7/ZrO2（MYZ）复合阻挡层。对 MYZ 涂层的微观结构、相组成和抗热震性进行了系统研究。烧结过程分为两个阶段。在初始阶段（25-1350°C），粒状莫来石晶粒逐渐转变为柱状晶体。同时，莫来石和 Y2Si2O7 的共晶复合体形成并分散在晶界中，显著提高了涂层的密度和附着力。在随后的阶段（∼1400°C），ZrO2 与共晶复合材料发生反应，在原位生成钇稳定氧化锆（YSZ）。YSZ 相与基底的界面相容性极佳，显著提高了涂层的高温稳定性。因此，涂层获得了高硬度，热膨胀系数与碳化硅基底相当。值得注意的是，MYZ 涂层经受住了 25°C 至 1200°C 20 次热循环的考验，而没有出现明显的界面损坏。

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来源期刊

Journal of the American Ceramic Society 工程技术-材料科学：硅酸盐

CiteScore

7.50

自引率

7.70%

发文量

590

审稿时长

2.1 months

期刊介绍： The Journal of the American Ceramic Society contains records of original research that provide insight into or describe the science of ceramic and glass materials and composites based on ceramics and glasses. These papers include reports on discovery, characterization, and analysis of new inorganic, non-metallic materials; synthesis methods; phase relationships; processing approaches; microstructure-property relationships; and functionalities. Of great interest are works that support understanding founded on fundamental principles using experimental, theoretical, or computational methods or combinations of those approaches. All the published papers must be of enduring value and relevant to the science of ceramics and glasses or composites based on those materials. Papers on fundamental ceramic and glass science are welcome including those in the following areas: Enabling materials for grand challenges[...] Materials design, selection, synthesis and processing methods[...] Characterization of compositions, structures, defects, and properties along with new methods [...] Mechanisms, Theory, Modeling, and Simulation[...] JACerS accepts submissions of full-length Articles reporting original research, in-depth Feature Articles, Reviews of the state-of-the-art with compelling analysis, and Rapid Communications which are short papers with sufficient novelty or impact to justify swift publication.