A new molten CMAS resistance strategy for PS-PVD Thermal Barrier Coatings based on laser-textured and Al-modified bionic structure

A new molten CMAS resistance strategy for PS-PVD Thermal Barrier Coatings based on laser-textured and Al-modified bionic structure | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Article A new molten CMAS resistance strategy for PS-PVD Thermal Barrier Coatings based on laser-textured and Al-modified bionic structure Xiaofeng Zhang, Xueshi Zhuo, Xiaomao Sun, Jian Wu, Hao Dong, Peng Shen, and 3 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-4558480/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 22 Aug, 2024 Read the published version in npj Materials Degradation → Version 1 posted 11 You are reading this latest preprint version Abstract Plasma spray-physical vapor deposition (PS-PVD) is a promising third-generation thermal barrier coatings (TBCs) technique. Feather-like columnar TBCs with excellent strain tolerance and low thermal conductivity can be achieved using PS-PVD. However, molten CMAS (CaO-MgO-Al 2 O 3 -SiO 2 ) can penetrate coatings and accelerate PS-PVD TBC failure due to the feather-like columnar structure. Hence, a strategy is proposed to alleviate molten CMAS corrosion. The super-hydrophobicity structure is fabricated via laser texturing on the surface of PS-PVD TBCs to repel molten CMAS wetting and spreading. Then, a thin layer of the Al-film is deposited on the laser-textured surface. Moreover, the Al-modified layer is in-situ synthesized after vacuum heat treatment, preventing the infiltration of molten CMAS into the TBCs and reducing the coating damage. The results show that the contact angle of laser textured and Al-modified PS-PVD TBCs (LT-Al) at room temperature increased from 12.3° to 168.8°. The wetting and spreading behavior of molten CMAS of as-sprayed (AS), laser textured (LT), and LT-Al coatings is observed in situ at 1250 ℃ for 1,800 s. The LT-Al coating exhibited excellent CMAS corrosion resistance, attributed to the laser-textured micro-nano structures and Al-modified layer protection. The findings may be an effective approach for solving the weakness of PS-PVD feather-like columnar structure TBCs. Physical sciences/Materials science/Structural materials/Ceramics Physical sciences/Engineering/Aerospace engineering PS-PVD thermal barrier coatings Femtosecond laser texture Al-modification CMAS Super-hydrophobicity Full Text Additional Declarations (Not answered) Supplementary Files Supplementaryvideo1.mp4 Supplementary video 1 Supplementaryvideo2.mp4 Supplementary video 2 Supplementaryvideo3.mp4 Supplementary video 3 Supplementaryvideo4.mp4 Supplementary video 4 Cite Share Download PDF Status: Published Journal Publication published 22 Aug, 2024 Read the published version in npj Materials Degradation → Version 1 posted Editorial decision: revise 28 Jun, 2024 Review # 3 received at journal 27 Jun, 2024 Reviewer # 3 agreed at journal 21 Jun, 2024 Review # 2 received at journal 20 Jun, 2024 Review # 1 received at journal 17 Jun, 2024 Reviewer # 2 agreed at journal 14 Jun, 2024 Reviewer # 1 agreed at journal 14 Jun, 2024 Reviewers invited by journal 14 Jun, 2024 Editor assigned by journal 12 Jun, 2024 Submission checks completed at journal 12 Jun, 2024 First submitted to journal 10 Jun, 2024 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-4558480","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Article","associatedPublications":[],"authors":[{"id":314293108,"identity":"a79c2145-2562-4795-8277-64a1072ccb72","order_by":0,"name":"Xiaofeng Zhang","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAy0lEQVRIiWNgGAWjYFACxocPEgxsePjZGxsffCBOC7OxwYeKNDnJnsPNhjOI1GImOePMYWODG+lt0hzEaJCfkcwgzduWljhz5sMGaQYGOzndBgJaGHsOMxjzttkk9ksnNhgXMCQbmx0g5Cz2/gPJYFtmJzYkz2A4kLiNkBY2ZmaGw7xthxM33DzYcJiHGC087M2MjRDvMzY2E6VFgucwMwMkkBObGWcYEOEXYIix/4BE5fHnPz5U2MkR1IIGDEhTPgpGwSgYBaMABwAANIhE4DWWJ0kAAAAASUVORK5CYII=","orcid":"https://orcid.org/0000-0002-7321-9631","institution":"Institute of New Materials, Guangdong Academy of Science","correspondingAuthor":true,"prefix":"","firstName":"Xiaofeng","middleName":"","lastName":"Zhang","suffix":""},{"id":314293109,"identity":"9bfa4706-e682-4b44-97eb-ca1b2a9f3ccc","order_by":1,"name":"Xueshi Zhuo","email":"","orcid":"","institution":"Xi’an Jiaotong University","correspondingAuthor":false,"prefix":"","firstName":"Xueshi","middleName":"","lastName":"Zhuo","suffix":""},{"id":314293110,"identity":"014cd689-88ba-4835-8541-c143de1b8d6b","order_by":2,"name":"Xiaomao Sun","email":"","orcid":"","institution":"Xi’an Jiaotong University","correspondingAuthor":false,"prefix":"","firstName":"Xiaomao","middleName":"","lastName":"Sun","suffix":""},{"id":314293111,"identity":"0ec81934-feb6-46c3-a5e5-5a219d6da357","order_by":3,"name":"Jian Wu","email":"","orcid":"","institution":"Institute of New Materials, Guangdong Academy of Sciences","correspondingAuthor":false,"prefix":"","firstName":"Jian","middleName":"","lastName":"Wu","suffix":""},{"id":314293112,"identity":"adf8f454-9831-4cc9-9ff2-49dd4f316af5","order_by":4,"name":"Hao Dong","email":"","orcid":"","institution":"Institute of New Materials, Guangdong Academy of Sciences","correspondingAuthor":false,"prefix":"","firstName":"Hao","middleName":"","lastName":"Dong","suffix":""},{"id":314293113,"identity":"b9794572-8ca2-485c-98bd-52f7a3858be0","order_by":5,"name":"Peng Shen","email":"","orcid":"","institution":"Xi’an Jiaotong University","correspondingAuthor":false,"prefix":"","firstName":"Peng","middleName":"","lastName":"Shen","suffix":""},{"id":314293114,"identity":"cc4f110c-5d44-47e3-aa62-8d861f44f1ba","order_by":6,"name":"Xuesong Mei","email":"","orcid":"","institution":"Xi’an Jiaotong University","correspondingAuthor":false,"prefix":"","firstName":"Xuesong","middleName":"","lastName":"Mei","suffix":""},{"id":314293115,"identity":"440cecd4-79f7-4e33-b161-7cf73ad7bd6e","order_by":7,"name":"Jianlei Cui","email":"","orcid":"","institution":"Xi’an Jiaotong University","correspondingAuthor":false,"prefix":"","firstName":"Jianlei","middleName":"","lastName":"Cui","suffix":""},{"id":314293116,"identity":"b4a99133-4f8b-4c55-b2bc-10ef650d01c8","order_by":8,"name":"Zhengjie Fan","email":"","orcid":"","institution":"Xi’an Jiaotong University","correspondingAuthor":false,"prefix":"","firstName":"Zhengjie","middleName":"","lastName":"Fan","suffix":""}],"badges":[],"createdAt":"2024-06-10 13:55:20","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-4558480/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-4558480/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1038/s41529-024-00505-2","type":"published","date":"2024-08-22T04:00:00+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":63998000,"identity":"54165343-0fc6-4bb4-b4c7-47fd4a805fe1","added_by":"auto","created_at":"2024-09-04 18:03:39","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":2452554,"visible":true,"origin":"","legend":"","description":"","filename":"Articlefile.pdf","url":"https://assets-eu.researchsquare.com/files/rs-4558480/v1_covered_aa1a3234-2d58-49e7-bc58-45ec1cca0ee6.pdf"},{"id":59371379,"identity":"f7056b41-a701-45a0-b1d6-c606c5032723","added_by":"auto","created_at":"2024-07-01 02:38:43","extension":"mp4","order_by":1,"title":"","display":"","copyAsset":false,"role":"supplement","size":18957885,"visible":true,"origin":"","legend":"\u003cp\u003eSupplementary video 1\u003c/p\u003e","description":"","filename":"Supplementaryvideo1.mp4","url":"https://assets-eu.researchsquare.com/files/rs-4558480/v1/c36c91cd52e2ff984ff2d59a.mp4"},{"id":59371374,"identity":"6ff2e101-a1a4-4d91-9731-ac0f9f4c084b","added_by":"auto","created_at":"2024-07-01 02:38:41","extension":"mp4","order_by":2,"title":"","display":"","copyAsset":false,"role":"supplement","size":2311775,"visible":true,"origin":"","legend":"Supplementary video 2","description":"","filename":"Supplementaryvideo2.mp4","url":"https://assets-eu.researchsquare.com/files/rs-4558480/v1/5c73a68859838dccb2581a43.mp4"},{"id":59371375,"identity":"1efd35cd-9857-4626-8fa6-b15b160df37a","added_by":"auto","created_at":"2024-07-01 02:38:42","extension":"mp4","order_by":3,"title":"","display":"","copyAsset":false,"role":"supplement","size":3987446,"visible":true,"origin":"","legend":"\u003cp\u003eSupplementary video 3\u003c/p\u003e","description":"","filename":"Supplementaryvideo3.mp4","url":"https://assets-eu.researchsquare.com/files/rs-4558480/v1/abc8174d9aca7871b400c27c.mp4"},{"id":59371382,"identity":"617cd661-4d23-47fd-bf86-4f4125717693","added_by":"auto","created_at":"2024-07-01 02:38:45","extension":"mp4","order_by":4,"title":"","display":"","copyAsset":false,"role":"supplement","size":1300337,"visible":true,"origin":"","legend":"\u003cp\u003eSupplementary video 4\u003c/p\u003e","description":"","filename":"Supplementaryvideo4.mp4","url":"https://assets-eu.researchsquare.com/files/rs-4558480/v1/c252a8a223ac4b6666a26909.mp4"}],"financialInterests":"(Not answered)","formattedTitle":"A new molten CMAS resistance strategy for PS-PVD Thermal Barrier Coatings based on laser-textured and Al-modified bionic structure","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"npj-materials-degradation","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"npjmatdeg","sideBox":"Learn more about [npj Materials Degradation](http://www.nature.com/npjmatdeg/)","snPcode":"41529","submissionUrl":"https://submission.springernature.com/new-submission/41529/3","title":"npj Materials Degradation","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"NPJ","inReviewEnabled":true,"inReviewRevisionsEnabled":true},"keywords":"PS-PVD thermal barrier coatings, Femtosecond laser texture, Al-modification, CMAS, Super-hydrophobicity","lastPublishedDoi":"10.21203/rs.3.rs-4558480/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-4558480/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003ePlasma spray-physical vapor deposition (PS-PVD) is a promising third-generation thermal barrier coatings (TBCs) technique. Feather-like columnar TBCs with excellent strain tolerance and low thermal conductivity can be achieved using PS-PVD. However, molten CMAS (CaO-MgO-Al\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-SiO\u003csub\u003e2\u003c/sub\u003e) can penetrate coatings and accelerate PS-PVD TBC failure due to the feather-like columnar structure. Hence, a strategy is proposed to alleviate molten CMAS corrosion. The super-hydrophobicity structure is fabricated via laser texturing on the surface of PS-PVD TBCs to repel molten CMAS wetting and spreading. Then, a thin layer of the Al-film is deposited on the laser-textured surface. Moreover, the Al-modified layer is in-situ synthesized after vacuum heat treatment, preventing the infiltration of molten CMAS into the TBCs and reducing the coating damage. The results show that the contact angle of laser textured and Al-modified PS-PVD TBCs (LT-Al) at room temperature increased from 12.3\u0026deg; to 168.8\u0026deg;. The wetting and spreading behavior of molten CMAS of as-sprayed (AS), laser textured (LT), and LT-Al coatings is observed in situ at 1250 ℃ for 1,800 s. The LT-Al coating exhibited excellent CMAS corrosion resistance, attributed to the laser-textured micro-nano structures and Al-modified layer protection. The findings may be an effective approach for solving the weakness of PS-PVD feather-like columnar structure TBCs.\u003c/p\u003e","manuscriptTitle":"A new molten CMAS resistance strategy for PS-PVD Thermal Barrier Coatings based on laser-textured and Al-modified bionic structure","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2024-07-01 02:38:22","doi":"10.21203/rs.3.rs-4558480/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"revise","date":"2024-06-28T13:50:14+00:00","index":"","fulltext":""},{"type":"editorInvitedReview","content":"This content is not available.","date":"2024-06-27T08:08:54+00:00","index":3,"fulltext":"This content is not available."},{"type":"reviewerAgreed","content":"This content is not available.","date":"2024-06-21T07:37:21+00:00","index":3,"fulltext":"This content is not available."},{"type":"editorInvitedReview","content":"This content is not available.","date":"2024-06-21T01:50:02+00:00","index":2,"fulltext":"This content is not available."},{"type":"editorInvitedReview","content":"This content is not available.","date":"2024-06-17T14:37:47+00:00","index":1,"fulltext":"This content is not available."},{"type":"reviewerAgreed","content":"This content is not available.","date":"2024-06-15T02:46:09+00:00","index":2,"fulltext":"This content is not available."},{"type":"reviewerAgreed","content":"This content is not available.","date":"2024-06-14T05:37:58+00:00","index":1,"fulltext":"This content is not available."},{"type":"reviewersInvited","content":"","date":"2024-06-14T05:02:31+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2024-06-13T00:41:03+00:00","index":"","fulltext":""},{"type":"checksComplete","content":"","date":"2024-06-12T14:09:10+00:00","index":"","fulltext":""},{"type":"submitted","content":"npj Materials Degradation","date":"2024-06-10T13:50:54+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"npj-materials-degradation","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"npjmatdeg","sideBox":"Learn more about [npj Materials Degradation](http://www.nature.com/npjmatdeg/)","snPcode":"41529","submissionUrl":"https://submission.springernature.com/new-submission/41529/3","title":"npj Materials Degradation","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"NPJ","inReviewEnabled":true,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"86502e6a-1250-4beb-8ded-02f08a7206ae","owner":[],"postedDate":"July 1st, 2024","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[{"id":33240111,"name":"Physical sciences/Materials science/Structural materials/Ceramics"},{"id":33240112,"name":"Physical sciences/Engineering/Aerospace engineering"}],"tags":[],"updatedAt":"2024-09-04T17:10:54+00:00","versionOfRecord":{"articleIdentity":"rs-4558480","link":"https://doi.org/10.1038/s41529-024-00505-2","journal":{"identity":"npj-materials-degradation","isVorOnly":false,"title":"npj Materials Degradation"},"publishedOn":"2024-08-22 04:00:00","publishedOnDateReadable":"August 22nd, 2024"},"versionCreatedAt":"2024-07-01 02:38:22","video":"","vorDoi":"10.1038/s41529-024-00505-2","vorDoiUrl":"https://doi.org/10.1038/s41529-024-00505-2","workflowStages":[]},"version":"v1","identity":"rs-4558480","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-4558480","identity":"rs-4558480","version":["v1"]},"buildId":"qtupq5eGEP_6zYnWcrvyt","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}