Structure and property evolution of LaYbZr2O7/YSZ heterogeneous interface in double-layer thermal barrier coatings after thermal exposure

Double-layer thermal barrier coatings are one of the development directions of thermal barrier coatings technology. LaYbZr2O7 (LYZO) has high toughness and low thermal conductivity, making it promising for use as a high-temperature thermal barrier coating. However, its relatively poor mechanical properties, especially low fracture toughness, limit its further application. Therefore, we prepared a double-layer coating of LYZO and Y2O3 partially stabilized ZrO2(YSZ) using atmospheric plasma spraying, with the inner layer being YSZ and the outer layer being LYZO. The results showed that after spraying, LYZO was in the metastable fluorite phase, while YSZ was in the tetragonal phase. LYZO and YSZ had good chemical compatibility, and an interaction layer formed at the interface between them, with its thickness increasing with the sintering time. Eventually, after 100 h of heat treatment, the thickness reached 12 mu m. The hardness of the LYZO/YSZ interface increased with the sintering time, reaching a maximum value after sintering at 1300 degrees C for 10 h. When evaluating the interfacial bonding strength using indentation method, the length of cracks caused by indentation significantly decreased with the increase of sintering time. The increase in bonding strength can be attributed to the formation of a reaction layer and the reduction of thermal residual stresses. Raman spectroscopy was used to measure the thermal residual strain at the LYZO/YSZ interface. Unbalanced distribution of thermal residual stress and M phase was observed near the interface. As the sintering time increased, both thermal residual stress and M phase content decreased. In summary, the double-layer thermal barrier coating of LYZO/YSZ has good potential for development.