High Growth Rate YSZ Thermal Barrier Coatings Deposited by MOCVD Demonstrate High Thermal Cycling Lifetime
Yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBC) were prepared by metalorganic chemical vapor deposition (MOCVD) using Y(OBut{sup n}){sub 3}, Zr(OBut{sup n}){sub 4} precursors and O{sub 2} 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, 1 kPa, n{sub O}/(n{sub Y} + n{sub Zr}) > 30, n{sub Y}/(n{sub Y} + n{sub Zr}) = 0.06-0.10 (fixed n{sub C}, n{sub H}). Experimental YSZ growth had multiple phases (fcc, monoclinic), had a relatively high growth rate (43 {micro}m/h, 1005 C), had an Arrhenius dependence (845-950 C, E{sub a} = 53.8 {+-} 7.9 kJ/mol), had columnar grains (SEM analysis), and had a coating through-thickness n{sub Y}/(n{sub Y} + n{sub Zr}) = 0.04 (EPMA analysis). Doubling the inlet yttrium precursor mole fraction resulted in fcc YSZ growth with a coating through-thickness n{sub Y}/(n{sub Y} + n{sub Zr}) = 0.07. Hot-insertion thermal cycling of YSZ coatings on FeCrAlY bond coats showed >1000 h lifetime, matching current standards for EB-PVD YSZ coatings.