Microstructure and thermal diffusivity of Gd2Zr2O7 powders

The selection of new TBC materials is restricted by few basic requirements such as: high melting point, no phase transformation between room and the operation temperatures, low thermal conductivity, chemical inertness to the combustion gases and environment, thermal expansion match with the metallic substrate, good adherence to the metallic substrate and low sintering rate of the porous microstructure. Among these properties, one of the most important is thermal diffusivity. The number of material that can be used as TBCs is limited and so far only a few materials have been found to basically satisfy these requirements. Recent research has shown that certain rare-earth zirconates, such as Gd2Zr2O7, have even lower thermal conductivities than 7YSZ, and this has spurred an intensive research in discovering alternative TBC materials. The results of microstructure tests performed on the powders intended for thermally sprayed TBCs with APS method were presented in this article. The tests of phase and chemical composition of the analysed powder were performed. The carbon, sulphur and gas nitrogen contents were, among other things, determined during those tests. The x-ray powder diffraction phase identification in as received material was determined. The tested material showed the presence of Gd2Zr2O7 compound as the predominant one and Gd2O3 and ZrO2 oxides. The surface morphology analysis of the powder was carried out and its internal structure was characterized. The tested material shows porous structure typical for agglomerated powders. The second testing area applied to analysis of the powder thermal properties. The thermal diffusivity of the compressed samples with density similar to the solid material was determined with the laser flash (LF) method. The measurement results show that requirements for the materials used for new generation TBCs are met.