IMPERMEABLE THIN Al{sub 2}O{sub 3} OVERLAY FOR TBC PROTECTION FROM SULFATE AND VANADATE ATTACK IN GAS TURBINES

In order to further improve the hot corrosion resistance of yttria-stabilized zirconia (YSZ), an Al{sub 2}O{sub 3} overlay of 58 {micro}m thick was deposited on the surface of YSZ by electron-beam physical vapor deposition. Hot corrosion tests were performed on the YSZ coatings with {gamma}-Al{sub 2}O{sub 3} overlay and {alpha}-Al{sub 2}O{sub 3} overlay in molten salt mixture (Na2SO4 + 5wt%V2O5) at 950 C. The {alpha}-Al{sub 2}O{sub 3} overlay was obtained by the post-annealing of g-Al{sub 2}O{sub 3} overlay at 1200 C for 1h. The results showed that compared with the hot corrosion resistance of YSZ coating with 25 {micro}m thick {gamma}-Al{sub 2}O{sub 3} overlay, either thickening {gamma}-Al{sub 2}O{sub 3} overlay or employing {alpha}-Al{sub 2}O{sub 3} overlay could impair the hot corrosion resistance of YSZ coating, because the tensile stresses developed in the alumina overlay in both cases due to the mismatch in thermal expansion coefficient (TEC) between alumina and zirconia resulted in cracking of Al{sub 2}O{sub 3} overlay. The formation of cracks increased contact area between molten salt and Al{sub 2}O{sub 3} overlay, and also the penetration rate of molten salt into Al{sub 2}O{sub 3} overlay and YSZ coating, leading a faster and greater degradation of YSZ coating upon exposure. In the next reporting period, we will study the effect of Al{sub 2}O{sub 3} overlay thickness on hot corrosion and spalling of YSZ coatings