High-growth rate YSZ thermal barrier coatings deposited by MOCVD demonstrate high thermal cycling lifetime

V. G. Varanasi; T. M. Besmann; E. A. Payzant; B. A. Pint; J. L. Lothian; T. J. Anderson

doi:10.1016/j.msea.2010.09.063

High-growth rate YSZ thermal barrier coatings deposited by MOCVD demonstrate high thermal cycling lifetime

V. G. Varanasi, T. M. Besmann, E. A. Payzant, B. A. Pint, J. L. Lothian, T. J. Anderson

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Abstract

Yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBC) were prepared by metalorganic chemical vapor deposition (MOCVD) using Y(OButⁿ)₃, Zr(OButⁿ)₄ precursors and O₂ carrier gas. A thermodynamic analysis guided experiments by optimizing elemental molar (n) stoichiometric ratios for the (Zr-Y-O-C-H system). This analysis showed single-phase YSZ was favored at 950°C, 1kPa, n_O/(n_Y+n_Zr)>30, n_Y/(n_Y+n_Zr)=0.06-0.10 (fixed n_C, n_H). Experimental YSZ growth had multiple phases (fcc, monoclinic), had a relatively high growth rate (43μm/h, 1005°C), had an Arrhenius dependence (845-950°C, E_a=53.8±7.9kJ/mol), had columnar grains (SEM analysis), and had a coating through-thickness n_Y/(n_Y+n_Zr)=0.04 (EPMA analysis). Doubling the inlet yttrium precursor mole fraction resulted in fcc YSZ growth with a coating through-thickness n_Y/(n_Y+n_Zr)=0.07. Hot-insertion thermal cycling of YSZ coatings on FeCrAlY bond coats showed >1000h lifetime, matching current standards for EB-PVD YSZ coatings.

Original language	English
Pages (from-to)	978-985
Number of pages	8
Journal	Materials Science and Engineering: A
Volume	528
Issue number	3
DOIs	https://doi.org/10.1016/j.msea.2010.09.063
State	Published - Jan 25 2011

Funding

The authors would like to thank J. Henry, J. McLaughlin, K. Cooley, T. Starr, W. Xu, S. Speakman, N. Kulkarni, for their discussions of this project. The research was sponsored by the Office of Fossil Energy, National Energy Technology Laboratory, U.S. Department of Energy, under contract number DE-AC05-00OR22725 with UT-Battelle, LLC. The XRD characterization was supported by the Assistant Secretary for Energy Efficiency and Renewable Energy, Office of Vehicle Technologies, as part of the High Temperature Materials Laboratory User Program, Oak Ridge National Laboratory.

Keywords

Aerosol-assisted liquid delivery
Butoxide precursor
Metalorganic chemical vapor deposition
Thermal barrier coating
Yttria-stabilized zirconia

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10.1016/j.msea.2010.09.063

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title = "High-growth rate YSZ thermal barrier coatings deposited by MOCVD demonstrate high thermal cycling lifetime",

abstract = "Yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBC) were prepared by metalorganic chemical vapor deposition (MOCVD) using Y(OButn)3, Zr(OButn)4 precursors and O2 carrier gas. A thermodynamic analysis guided experiments by optimizing elemental molar (n) stoichiometric ratios for the (Zr-Y-O-C-H system). This analysis showed single-phase YSZ was favored at 950°C, 1kPa, nO/(nY+nZr)>30, nY/(nY+nZr)=0.06-0.10 (fixed nC, nH). Experimental YSZ growth had multiple phases (fcc, monoclinic), had a relatively high growth rate (43μm/h, 1005°C), had an Arrhenius dependence (845-950°C, Ea=53.8±7.9kJ/mol), had columnar grains (SEM analysis), and had a coating through-thickness nY/(nY+nZr)=0.04 (EPMA analysis). Doubling the inlet yttrium precursor mole fraction resulted in fcc YSZ growth with a coating through-thickness nY/(nY+nZr)=0.07. Hot-insertion thermal cycling of YSZ coatings on FeCrAlY bond coats showed >1000h lifetime, matching current standards for EB-PVD YSZ coatings.",

keywords = "Aerosol-assisted liquid delivery, Butoxide precursor, Metalorganic chemical vapor deposition, Thermal barrier coating, Yttria-stabilized zirconia",

author = "Varanasi, {V. G.} and Besmann, {T. M.} and Payzant, {E. A.} and Pint, {B. A.} and Lothian, {J. L.} and Anderson, {T. J.}",

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AU - Varanasi, V. G.

AU - Besmann, T. M.

AU - Payzant, E. A.

AU - Pint, B. A.

AU - Lothian, J. L.

AU - Anderson, T. J.

PY - 2011/1/25

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N2 - Yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBC) were prepared by metalorganic chemical vapor deposition (MOCVD) using Y(OButn)3, Zr(OButn)4 precursors and O2 carrier gas. A thermodynamic analysis guided experiments by optimizing elemental molar (n) stoichiometric ratios for the (Zr-Y-O-C-H system). This analysis showed single-phase YSZ was favored at 950°C, 1kPa, nO/(nY+nZr)>30, nY/(nY+nZr)=0.06-0.10 (fixed nC, nH). Experimental YSZ growth had multiple phases (fcc, monoclinic), had a relatively high growth rate (43μm/h, 1005°C), had an Arrhenius dependence (845-950°C, Ea=53.8±7.9kJ/mol), had columnar grains (SEM analysis), and had a coating through-thickness nY/(nY+nZr)=0.04 (EPMA analysis). Doubling the inlet yttrium precursor mole fraction resulted in fcc YSZ growth with a coating through-thickness nY/(nY+nZr)=0.07. Hot-insertion thermal cycling of YSZ coatings on FeCrAlY bond coats showed >1000h lifetime, matching current standards for EB-PVD YSZ coatings.

AB - Yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBC) were prepared by metalorganic chemical vapor deposition (MOCVD) using Y(OButn)3, Zr(OButn)4 precursors and O2 carrier gas. A thermodynamic analysis guided experiments by optimizing elemental molar (n) stoichiometric ratios for the (Zr-Y-O-C-H system). This analysis showed single-phase YSZ was favored at 950°C, 1kPa, nO/(nY+nZr)>30, nY/(nY+nZr)=0.06-0.10 (fixed nC, nH). Experimental YSZ growth had multiple phases (fcc, monoclinic), had a relatively high growth rate (43μm/h, 1005°C), had an Arrhenius dependence (845-950°C, Ea=53.8±7.9kJ/mol), had columnar grains (SEM analysis), and had a coating through-thickness nY/(nY+nZr)=0.04 (EPMA analysis). Doubling the inlet yttrium precursor mole fraction resulted in fcc YSZ growth with a coating through-thickness nY/(nY+nZr)=0.07. Hot-insertion thermal cycling of YSZ coatings on FeCrAlY bond coats showed >1000h lifetime, matching current standards for EB-PVD YSZ coatings.

KW - Aerosol-assisted liquid delivery

KW - Butoxide precursor

KW - Metalorganic chemical vapor deposition

KW - Thermal barrier coating

KW - Yttria-stabilized zirconia

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JO - Materials Science and Engineering: A

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ER -

High-growth rate YSZ thermal barrier coatings deposited by MOCVD demonstrate high thermal cycling lifetime

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