CMAS corrosion resistance of Gd2O3-Yb2O3-Y2O3-stabilized ZrO2 coatings with different surface states

CMAS corrosion resistance of Gd2O3-Yb2O3-Y2O3-stabilized ZrO2 coatings with different surface states | 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 Research Article CMAS corrosion resistance of Gd2O3-Yb2O3-Y2O3-stabilized ZrO2 coatings with different surface states Na Xu, Yiqing Sui, Lanxin Zou, Shuang Qin, Minghao Gao, Xinchun Chang This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6611295/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 4 You are reading this latest preprint version Abstract Thermal barrier coatings (TBCs), critical for enhancing the efficiency of aircraft engines, are susceptible to corrosion by CaO-MgO-Al 2 O 3 -SiO 2 (CMAS). In this study, Gd 2 O 3 -Yb 2 O 3 -Y 2 O 3 -stabilized ZrO 2 (GYYSZ) TBCs were prepared via atmospheric plasma spraying, and different surface states were obtained through mechanical grinding. The corrosion behavior of CMAS on coatings with different surface roughness was researched, and the corrosion mechanism was explained. The diffusion area of CMAS on the ground coatings surface is smaller, and the contact angle with the ground coatings is larger, compared with the coatings without mechanical polishing. Many spherical particles formed in the GYYSZ coatings after being corroded by CMAS at 1250°C, but demonstrating exceptional phase stability with retention of cubic phase throughout the 20 h exposure period. The ground coatings display fewer spherical particles than the as-sprayed coatings under the same corrosion conditions. The ground coatings manifest more residual CMAS on their surface, indicating that less CMAS penetrates into the coatings. This study suggests that the ground coatings significantly inhibit CMAS wetting and exhibit superior CMAS corrosion resistance compared to the as-sprayed coatings. thermal barrier coatings CMAS Gd2O3-Yb2O3-Y2O3-stabilized ZrO2 surface states wetting behavior corrosion mechanism Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Introduction Thermal barrier coatings (TBCs) are a kind of relatively low-cost technology used in high-temperature components of aircraft engines to provide thermal insulation, consequently enabling the high-temperature components to operate at higher temperature [ 1 – 3 ]. TBCs usually consist of bond coat and ceramic top coat [ 4 ]. YSZ is the most widely used ceramic top coat material because of its low thermal conductivity and thermal expansion coefficient closely matching that of the bond coat [ 5 – 7 ]. Nevertheless, YSZ coatings are inevitably affected by atmospheric dust, volcanic ash and other particles under actual service conditions. The main components of these environmental particles are CaO, MgO, Al 2 O 3 , SiO 2 , referred to as CMAS [ 8 – 10 ]. CMAS that adheres to the surface of YSZ melts at high temperatures, penetrates into the coatings through defects, causes phase transformations and reduces the porosity, thermal insulation, and strain tolerance [ 11 – 13 ]. This corrosive process will accelerate spallation of coatings and ultimately lead to the failure of TBCs. Improving the CMAS corrosion resistance of coatings has become a research focus in the field of TBCs [ 14 – 16 ]. Doping and modifying conventional YSZ [ 17 – 19 ] are common strategies to enhance the CMAS corrosion resistance of TBCs in addition to developing novel TBCs materials such as rare earth zirconates (RE 2 Zr 2 O 7 ) [ 20 – 22 ] and rare earth phosphates (REPO 4 ) [ 23 , 24 ]. Guo et al. [ 25 ] synthesized RE₂O₃-Yb₂O₃ co-doped YSZ (REYb-YSZ, RE = La, Nd, Gd) ceramics materials, which exhibited superior high-temperature phase stability and lower thermal conductivity than YSZ. Su et al. [ 26 ] conducted first-principles calculations and CMAS corrosion experiments on YSZ, Gd 2 Zr 2 O 7 and YSZ(Gd) to investigate how Gd element influences the CMAS corrosion behavior of zirconium-based coatings at high temperature. The results indicate that the existence of the Gd element decreases the diffusion coefficients of the Y, Zr and O elements, and the corrosion depth of Gd 2 Zr 2 O 7 and GdYSZ is lower than that of YSZ. It can be inferred that Gd element is beneficial to enhance the corrosion resistance of YSZ coatings under CMAS condition. Fang et al. [ 27 ] investigated the corrosion behavior of YSZ and YbYSZ under CMAS conditions using first-principles calculations and corrosion experiments. The results represent that YbYSZ has better corrosion resistance than YSZ under the condition of CMAS, which may be because the diffusion coefficient of Yb 3+ is lower than Y 3+ . Consequently, doping YSZ with Yb 2 O 3 can increase its resistance against CMAS corrosion. Bahamirian et al. [ 28 ] confirmed that 5.2Gd 2 O 3 -5.6Yb 2 O 3 -9.5Y 2 O 3 -ZrO 2 powder maintains exceptional phase stability after 50 h at 1300°C, highlighting its potential for TBCs applications. However, its CMAS corrosion resistance remains understudied. Many researchers have reported that optimizing the surface morphology of coatings can improve the CMAS corrosion resistance. Yan et al. [ 29 ] demonstrated that TBCs after laser-glazed treatment exhibit smooth surface and dense microstructure. Hence, the laser-modified coatings exhibited stronger resistance to CMAS corrosion compared to the as-sprayed coatings. Wang et al. [ 30 ] reported that the coatings with micro-nano double scale structures prepared by solution precursor plasma spray (SPPS) could help reduce CMAS wettability on the coatings and accordingly enhance corrosion resistance under CMAS exposure. Guo et al. [ 31 ] revealed the polished bulk materials exhibit better CMAS wetting resistance than the as-fabricated bulks, concluding that reduced surface roughness improves CMAS resistance. The critical role of coatings surface roughness on the wetting behavior of CMAS was also highlighted by Yang et al. [ 32 ] and Yin et al. [ 33 ]. In order to explore the interaction mechanism between CMAS and 5.2Gd 2 O 3 -5.6Yb 2 O 3 -9.5Y 2 O 3 -ZrO 2 (GYYSZ) coatings with different surface states, this study focused on three groups of atmospheric plasma spray (APS) GYYSZ coatings with varying surface roughness. The surface characteristics of one group of as-sprayed coatings and two groups of polished coatings were compared, and the wetting behavior and corrosion mechanism of GYYSZ coatings under CMAS exposure at 1250°C were investigated. Materials and methods 2.1 Preparation of coatings The composition and granularity of the GYYSZ powder used in this study were 5.2Gd 2 O 3 -5.6Yb 2 O 3 -9.5Y 2 O 3 -ZrO 2 (in wt%) and 30–74 µm, respectively. The preparation of GYYSZ coatings by atmospheric plasma spraying is a complex process. The voltage and arc current were 70 V and 590 A, respectively. The flow of primary plasma gas (Ar) and secondary plasma gas (H 2 ) were 38 slpm and 1.8 slpm. The spray distance was 90 mm, and the powder-feeding rate was 27 g·min − 1 . A pause of 1 min is necessary after every 3 passes by thermal spray gun to prevent the formation of large cracks in the coatings during the spraying process. It is easy to separate the coatings from the graphite substrates when the thickness of the deposited coatings is enough due to the significant difference in the coefficient of thermal expansion between graphite and GYYSZ. The coatings with different surface roughness were prepared by sandpaper. The original sprayed coatings without any treatment are named As-sprayed group. The other two groups, ground with 120#, 240#, and 320# sandpaper, are designated as the Rough grinding group and Fine grinding group. The 2D surface roughness (Ra) of the coatings was tested by the SJ-210 surface roughness meter (Mitutoyo, Kawasaki, Japan), and the specific data are listed in Table 1 . Table 1 Surface roughness values of three groups of GYYSZ coatings As-sprayed Rough grinding Fine grinding Ra (µm) 6.42–7.21 1.46–1.72 0.56–0.75 2.2 Preparation of CMAS powder The CMAS used in this study, composed of 33CaO-9MgO-13AlO 1.5 -45SiO 2 (mol%), was similar to the environmental deposits accumulated on the turbine shaft of aircraft operating in desert environments, as reported by Borom et al. [ 34 ]. Firstly, the weighed powders, zirconia balls and anhydrous ethanol were placed in a ceramic jar in a mass ratio of 1:2:1, respectively. Then the ceramic jar was put into the high-speed ball mill and run for 20 h. The obtained slurry was dried at 120°C for 6 h and then sintered at 1150°C for 24 h. Subsequent to ball milling and another drying process, the powder was further ground with a mortar and pestle to produce the final CMAS powder. 2.3 Wetting and corrosion tests The CMAS powder was pressed and cut into small pieces with the size of 3 × 3 × 1 mm. After the CMAS pieces were placed on the coating surfaces, the coatings were transferred to the furnace and held at 1250°C for 30 min. The coatings prepared for corrosion tests were coated with 20 mg·cm − 2 of CMAS and then put into the furnace and subjected to heat treatment at 1250°C for 1, 5 and 20 h, respectively. 2.4 Characterization The environmental scanning electron microscope (SEM, Quattro S, FEI, Eindhoven, The Netherlands) was employed to gather information about the cross-sectional and surface morphology as well as the chemical composition of GYYSZ coatings. The laser confocal microscope (LSM 700, Zeiss, Jena, Germany) was used to obtain 3D surface morphology, line roughness profiles, and the associated surface roughness values of the coatings prior to the tests. The X-ray diffractometer (XRD, SmartLab, Rigaku, Tokyo, Japan) was applied to characterize the phase composition of the as-sprayed coatings and corroded coatings. The spreading diameters of CMAS on the coatings and the contact angles of molten CMAS on the coating surfaces were measured by ImageJ 1.8.0. Results and discussion Figure 1 are SEM images about cross-sectional morphologies of the as-sprayed GYYSZ coatings. In Fig. 1 (b), many V-grooves are observed in the cross-sectional profile, resulting in an unsmooth coating surface morphology. Microcracks and pores can be found in the as-sprayed coating as shown in Fig. 1 (c). It is primarily attributed to inadequate interparticle overlap and incorporated air during the spraying process [ 35 ]. Although it can help enhance the thermal insulation properties of TBCs, it also creates channels for CMAS penetration [ 36 – 39 ]. EDS results of Point 1 in Fig. 1 (a), as listed in Table 2 , reveal that the composition of GYYSZ coatings is similar to that of GYYSZ powder, confirming the rationality of the selected spraying parameters. Table 2 EDS results of the Points 1–5 in Figs. 1 , 5 , 6 and 7 (in wt%) O Gd Yb Y Zr Ca Mg Al Si 1 20.76 5.1 6.03 9.1 59.01 - - - - 2 41.33 1.61 1.04 1.54 4.2 21.57 3.15 6.45 19.11 3 22.19 5.6 5.23 8.65 56.16 0.65 0.23 0.34 0.95 4 22.67 5.07 5.34 8.28 55.87 1.21 0.27 0.28 1.01 5 23.23 4.51 5.24 8.35 55.39 1.38 0.31 0.36 1.23 Surface morphology information of GYYSZ coatings with three different roughness is shown in Fig. 2 . The uneven surface morphology of the as-sprayed coatings is shown in Fig. 2 (a), which is due to the plasma spraying process. Notably, the surface has both rough and smooth regions. The rough regions are related to semi-melted and unmelted particles, while the smooth regions are related to melted particles [ 40 ]. These particles are continuously stacked on the substrate to form coatings. The surface morphology in Fig. 2 (a) and the 3D surface laser confocal images in Fig. 2 (b) both indicates that the depth of V-grooves on the surface of GYYSZ decreases with the decrease of the surface roughness of the coating. The removal of some shallow V-grooves and the persistence of some deep V-grooves on the coating surfaces are due to the preferential contact of the sandpaper with the raised portions of the coatings. The related line roughness profiles are shown in Fig. 2 (c). It can be found that the vales of 3D surface roughness parameter (Sa) and 2D surface roughness parameter of GYYSZ coatings are similar to the average values of the initially measured roughness shown in Table 1 . This consistency ensures the accuracy of the surface roughness measurements. It has been demonstrated that the contact angle between molten CMAS and the coating, and the spreading area of CMAS can be used as evaluation indices for assessing the corrosion resistance of the coatings under CMAS exposure [ 41 , 42 ]. A larger contact angle and a smaller spreading area mean superior CMAS wetting resistance [ 31 ]. Characterization results of GYYSZ coatings with three different roughness after CMAS wetting tests at 1250°C for 30 min are shown in Fig. 3 . The spread of melted CMAS on the surface of the coating can be observed in Fig. 3 (a), where the black dashed line represents the spread outer edge of molten CMAS. Figure 3 (b) clearly illustrates that the contact angle of molten CMAS and GYYSZ coatings with different surface roughness are also different. Figure 3 (c) shows the surface microstructure of the coatings after wetting experiment. The yellow dotted line represents the CMAS diffusion front, the dark area corresponds to CMAS, and the bright area represents GYYSZ coatings. It can be observed that CMAS at the spreading fronts exhibits low content and a discontinuous distribution, mainly in the V-grooves. It indicates the preferential flow of molten CMAS along the V-grooves. The experimental results shown in Fig. 3 are summarized in Fig. 4 . It is not difficult to find that with the decrease of surface roughness, the diffusion area of molten CMAS also decreases, and the contact angle between molten CMAS and the coatings increases. This suggests that coatings with shallow V-grooves are more difficult to wet by CMAS than coatings with deep V-grooves. The V-grooves structures on the solid surfaces are beneficial to improving the capillary force driving the spreading of liquid, as demonstrated by Yost et al. [ 43 ]. It showed that there is an increase in capillary force with increasing V-grooves depth. In other words, coatings with smaller surface V-grooves depth result in smaller capillary forces driving CMAS flow, leading to poorer flow ability of CMAS on shallow V-grooves compared to deep V-grooves. In addition to capillary action, the greater continuity of interconnection between V-grooves on the coating surfaces may make it easier for CMAS to spread outward. In contrast to the as-sprayed coating, the ground coatings exhibit smaller V-grooves depth and greater discontinuity in the interconnections between V-grooves. The driving force and the pathway for molten CMAS to spreading continuously are both diminished by the reduced V-grooves depth and continuity of interconnection between V-grooves, resulting in a superior CMAS wetting resistance of the ground coatings. The wetting behavior of CMAS on coatings is related to the surface microstructure of the coatings. Consequently, it is possible to strategically modify the surface microstructure of the coatings, aiming to minimize the wetting of CMAS to TBCs, accordingly mitigating the damage caused by CMAS in the coatings. Cross-sectional microstructures of the as-sprayed GYYSZ coatings without any treatment under CMAS exposure at 1250°C for 1, 5 and 20 h are shown in Fig. 5 – 7 , respectively. It is clear that spherical particles form in GYYSZ coatings after CMAS exposure at 1250°C for 1–20 h. Voids are observed in the residual CMAS layers as shown in Fig. 6 (b), possibly resulting from trapped gases within the coating escaping outward and being confined by CMAS [ 44 ]. Several key trends can be found in the corroded GYYSZ coatings with the extension of corrosion time. Firstly, there is a thickness reduction in residual CMAS on the coating surfaces, indicating the gradual infiltration of CMAS into the coatings. Secondly, the number of spherical particles in CMAS increases, and the quantity and size of spherical particles in the coating also increase significantly. This may be due to the prolonged interaction time between the coating and CMAS, as well as the growth of grain boundaries. Thirdly, the number of the voids observed in the residual CMAS layers increases with the extension of corrosion time, indicating the coatings continue to dissolve under CMAS exposure, resulting in more gas escaping from the pores in the coatings. Additionally, the sphericalization is not observed in the regions beneath the black dotted line (Fig. 5 (a)) in the coating corroded for 1 h. However, the sphericalization occurred at the bottom of the coatings after 5 h and 20 h of CMAS corrosion, as shown in Fig. 6 and Fig. 7 . This indicates a continuous increase in CMAS penetration depth into the coatings. GYYSZ coating is fully penetrated by CMAS after only 5 h of corrosion. The size of the spherical particles observed in the interior of GYYSZ coatings (Fig. 5 (d), Fig. 6 (c) and Fig. 7 (c)) is smaller than that on the surfaces of GYYSZ coatings (Fig. 5 (c), Fig. 6 (b) and Fig. 7 (b)). This may be related to the order of reactions between the coatings and CMAS, where the coating surface react with CMAS before the interior of the coatings [ 45 ]. EDS results of the Points 2–5 observed in Fig. 5 – 7 are shown in Table 2 . Point 2 is a random point within the CMAS region. However, the presence of rare earth and Zr elements is detected at this point through EDS analysis, indicating that coating elements can diffuse outward. It can be clearly seen from Table 2 that the contents of rare earth elements and zirconium elements is higher than that of Ca, Mg, Al, and Si in Points 3–5. There is a significant difference in the content of compared to the element content at Point 2. It can be inferred that the spherical particles are the result of coating elements dissolving under the influence of CMAS, then diffusing into the CMAS and re-precipitating. Combined with the XRD data in Fig. 8 , it can be speculated that the phase composition of the spherical particles is c-ZrO 2 . In addition, spherical particles are also observed inside the coatings, indicating that CMAS has diffused deep into the GYYSZ coatings. It also induces the dissolution and re-precipitation of rare earth elements and zirconium elements, resulting in the formation of spherical particles in the coatings similar to those in CMAS. Besides, Fig. 8 also shows that the coatings maintain cubic zirconia phase after corrosion in CMAS for 1, 5, and 20 hours, indicating excellent phase stability of GYYSZ coatings. CMAS corrosion tests are conducted on the as-sprayed and ground GYYSZ coatings to assess the CMAS corrosion resistance of the coatings with different surface states. Figure 9 is cross-sectional microstructures of GYYSZ coatings with different roughness exposed to CMAS for 5 h and 20 h. Figure 10 is surface morphologies of GYYSZ coatings with different roughness exposed to CMAS for 20 h. Two distinct layers are visible in the cross-sectional microstructures: the residual CMAS layer on the coatings surface and the underlying GYYSZ coatings. Spherical particles can be observed in the residual CMAS layer. This phenomenon is a result of the continuous dissolution and diffusion of rare earth elements from the coating into the CMAS, followed by their reprecipitation within the CMAS. Among the three groups of GYYSZ coatings, the residual CMAS content on the coating surface of Fine grinding was the highest, and the distribution density of spherical particles in residual CMAS was the lowest. This difference may be due to the different surface microstructure of the coating (as shown in Fig. 2 ). The overall distribution density of V-grooves on the coatings decreased after grinding the coatings surface, leading to a decrease in the specific surface area. This reduction results in a smaller area of the coatings interacting with CMAS, which weakens the reaction between the coatings and molten CMAS. Therefore, the dissolution rate of the coatings under CMAS exposure is reduced, and the formation of spherical particles is reduced. It can be inferred that grinding the coatings by sandpaper to reduce the distribution of V-grooves is beneficial for improving the corrosion resistance of the coatings to CMAS. A fewer V-grooves on the coating surfaces leads to a lower reactivity between the coatings and CMAS. In this study, the surface roughness of the coatings is positively correlated with the distribution of V-grooves on their surface. Thus, the corrosion resistance of the coatings to CMAS can be enhanced by decreasing the surface roughness of the coatings. Figure 11 is a schematic diagram of CMAS corrosion of GYYSZ coatings in the as-sprayed and ground states. Figure 11 (a) represents the initial state of interaction between as-sprayed GYYSZ coatings surface without polishing treatment and CMAS. There are pores and micro-cracks inside the coatings, and a large number of V-grooves on the surface of the as-sprayed coatings. These defects provide channels and reaction sites for CMAS attack. Figure 11 (b) shows that the molten CMAS completely spreads over the surface of the as-sprayed coatings and thoroughly wets the coatings. There will be interdiffusion of elements between coatings and CMAS. The Ca, Mg, Al, Si from CMAS penetrate into the coatings and induce a "dissolution-reprecipitation" reaction in the GYYSZ coatings, causing the formation of spherical particles in coatings. Some of the dissolved RE and zirconium elements diffuse into the CMAS and re-precipitate, leading to the formation of spherical particles within the CMAS as well. The spherical ZrO 2 particles are first formed near the interface between the corrosive medium and the coatings, as these regions are the initial zone of mutual diffusion. The structural integrity of the coatings gradually degraded with the further penetration of CMAS into the coatings, resulting in the release of gas originally wrapped in the coatings. Some of gases fail to escape in time and are retained during the cooling and solidification process of CMAS, thus forming pores in CMAS. It can be seen in Fig. 11 (c) that CMAS has deeply penetrated the coatings, the structure of the coatings has been damaged more seriously, and the diffusion of elements continues. The number of spherical ZrO 2 particles increased, as did the number and size of pores in CMAS. This implies that the interaction between CMAS and the coatings is intensified with the corrosion process, and the performance of the coatings deteriorates gradually. Figure 11 (d) demonstrates the initial state of interaction between the surface of the ground GYYSZ coating and CMAS. The surface of ground coatings is relatively flat, with small undulations and sparse distribution of V-grooves. The initially molten CMAS cannot immediately spread over the entire coating surface because of the smooth coatings surface, and there is a certain contact angle between CMAS and coatings, as shown in Fig. 11 (e). The smooth surface will also reduce the contact area between CMAS and coatings, incurring a slower infiltration of CMAS and reaction rate between CMAS and the coatings, and weaker initial interaction. Therefore, no obvious spherical ZrO 2 particles or numerous pores have formed yet. Figure 11 (f) reveals that although the ground coatings exhibit lower reactivity with CMAS, prolonged corrosion not only increases the number of spherical ZrO 2 particles in the coatings and CMAS, but also causes more gas to be trapped within the CMAS. However, fewer spherical particles and pores are formed compared to the as-sprayed coatings. It can be observed that there are more residual CMAS on the ground coatings surface (as shown in Fig. 9 ), indicating less CMAS infiltration into the coatings. The number of spherical particles formed on the surface of as-sprayed coatings is greater than that of ground coatings, which can be observed in Fig. 10 , implying that the as-sprayed coatings experience more elemental loss. Consequently, the CMAS corrosion resistance of the ground coatings is superior to the that of as-sprayed coatings. Conclusions GYYSZ coatings with different surface states were prepared by mechanical grinding. The wetting and corrosion behaviors of these coatings were systematically investigated and compared under CMAS corrosion. Results indicate that CMAS exhibits a reduced diffusion area on the mechanically ground GYYSZ coatings surface, along with an increased contact angle between molten CMAS and the coatings compared to the a-sprayed coatings. It was turned out that ground coatings possess better resistance to CMAS wettability. Lower surface roughness correlates with improved resistance to CMAS wettability, which attributed to the depth and density of V-grooves on the coating surface. The coating structure is damaged under the corrosion condition of CMAS at 1250°C. Due to the interdiffusion of elements between CMAS and GYYSZ coatings, the "dissolution-reprecipitation" reaction occurred in CMAS and coatings and spherical ZrO 2 particles were formed in the coatings and CMAS. In comparison to as-sprayed coatings, the ground coatings demonstrate more residual CMAS on the surface and fewer spherical particles. Notably, GYYSZ maintains the cubic zirconia phase after 20 h of exposure to CMAS at 1250°C, exhibiting excellent phase stability. These findings substantiate that reducing surface roughness enhances the corrosion resistance of GYYSZ coatings against CMAS, providing valuable insights into the corrosion mechanism of CMAS on multi-rare earth oxide-stabilized zirconia TBCs. Declarations Conflict of Interest The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper. Ethical approval Not applicable Author contributions Na Xu: original draft, conceptualization, methodology, validation, supervision and funding acquisition. Yiqing Sui: investigation, writing, review, editing, formal analysis, visualization and conceptualization. Lanxin Zou: investigation, writing, editing, visualization and formal analysis. Shuang Qin: formal analysis and review. Minghao Gao: methodology, supervision and formal analysis. Xinchun Chang: funding acquisition. Acknowledgements The authors gratefully acknowledge the financial support from GFang Basic Research Program Funds (JCKY2021204A004). Data availability All datasets generated or analyzed during the current study are described as presented figures or tables. The data used in this study are available upon request. References Vaßen, R., Jarligo, M. O., Steinke, T., Mack, D. E., & Stöever, D. (2010). Overview on advanced thermal barrier coatings. Surface & Coatings Technology , 205 , 938–942. https://doi.org/10.1016/j.surfcoat.2010.08.151 Miller, R. A. (1987). Current status of thermal barrier coatings - An overview. Surface & Coatings Technology , 30 , 1–11. https://doi.org/10.1016/0257-8972(87)90003-X Thakare, J. G., Pandey, C., Mahapatra, M. M., & Mulik, R. S. (2021). Thermal barrier coatings-A state of the art review. 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C., & Ma, W. (2023). CMAS corrosion behavior of a LaPO 4 ceramic prepared by spark plasma sintering. Journal Of The American Ceramic Society , 106 , 5420–5430. https://doi.org/10.1111/jace.1916 Guo, L., Li, M., & Ye, F. (2016). Phase stability and thermal conductivity of RE 2 O 3 (RE = La, Nd, Gd, Yb) and Yb 2 O 3 co-doped Y 2 O 3 stabilized ZrO 2 ceramics. Ceramic International , 42 , 7360–7365. https://doi.org/10.1016/j.ceramint.2016.01.138 Su, Q., Zhang, Y., Li, G., Geng, Y., Zheng, H., Chen, Z., & Peng, P. (2021). Doped effect of Gd and Y elements on corrosion resistance of ZrO 2 in CMAS melt: First-principles and experimental study. Journal Of The European Ceramic Society , 41 , 7893–7901. https://doi.org/10.1016/j.jeurceramsoc.2021.09.002 Fang, H., Wang, W., Huang, J., Li, Y., & Ye, D. (2021). Corrosion behavior and thermos-physical properties of a promising Yb 2 O 3 and Y 2 O 3 co-stabilized ZrO 2 ceramic for thermal barrier coatings subject to calcium-magnesium-aluminum-silicate (CMAS) deposition: Experiments and first-principles calculation. Corrosion Science , 182 , 109230. https://doi.org/10.1016/j.corsci.2020.109230 Bahamirian, M., Hadavi, S. M. M., Farvizi, M., Rahimipour, M. R., & Keyvani, A. (2019). Phase stability of ZrO 2 9.5Y 2 O 3 5.6Yb 2 O 3 5.2Gd 2 O 3 compound at 1100°C and 1300°C for advanced TBC applications. Ceramic International , 45 , 7344–7350. https://doi.org/10.1016/j.ceramint.2019.01.018 Yan, Z., Guo, L., Li, Z., Yu, Y., & He, Q. (2019). Effects of laser glazing on CMAS corrosion behavior of Y 2 O 3 stabilized ZrO 2 thermal barrier coatings. Corrosion Science , 157 , 450–461. https://doi.org/10.1016/j.corsci.2019.06.025 Wang, Y., Xu, Z., Wang, W., Zhang, C., Yu, Z., Fang, H., & Yang, T. (2022). Preparation and CMAS Wettability investigation of CMAS corrosion resistant protective layer with micro-nano double scale structure. Coatings , 12 , 648. https://doi.org/10.3390/coatings12050648 Guo, L., Li, G., & Gan, Z. (2021). Effects of surface roughness on CMAS corrosion behavior for thermal barrier coating applications. J Adv Ceram , 10 , 472–481. https://doi.org/10.1007/s40145-020-0449-7 Yang, S. J., Song, W. J., Dingwell, D. B., He, J., & Guo, H. B. (2022). Surface roughness affects metastable non-wetting behavior of silicate melts on thermal barrier coatings. Rare Metals , 41 , 469–481. https://doi.org/10.1007/s12598-021-01773-6 Yin, B., Sun, M., Zhu, W., Yang, L., & Zhou, Y. (2021). Wetting and spreading behaviour of molten CMAS towards thermal barrier coatings and its influencing factors. Results Phys , 26 , 104365. https://doi.org/10.1016/j.rinp.2021.104365 Borom, M. P., Johnson, C. A., & Peluso, L. A. (1996). Role of environmental deposits and operating surface temperature in spallation of air plasma sprayed thermal barrier coatings. Surface & Coatings Technology , 86–87 , 116–126. https://doi.org/10.1016/S0257-8972(96)02994-5 Verdian, M. M., Raeissi, K., & Salehi, M. (2010). Corrosion performance of HVOF and APS thermally sprayed NiTi intermetallic coatings in 3.5% NaCl solution. Corrosion Science , 52 , 1052–1059. https://doi.org/10.1016/j.corsci.2009.11.034 Wang, L., Wang, Y., Sun, X. G., He, J. Q., Pan, Z. Y., Zhou, Y., & Wu, P. L. (2011). Influence of pores on the thermal insulation behavior of thermal barrier coatings prepared by atmospheric plasma spray. Materials And Design , 32 , 36–47. https://doi.org/10.1016/j.matdes.2010.06.040 Zhang, W. W., Wei, Z. Y., Zhang, L. Y., Xing, Y. Z., & Zhang, Q. (2020). Low-thermal-conductivity thermal barrier coatings with a multi-scale pore design and sintering resistance following thermal exposure. Rare Metals , 39 , 352–367. https://doi.org/10.1007/s12598-020-01393-6 Shan, X., Luo, L., Chen, W., Zou, Z., Guo, F., He, L., Zhang, A., Zhao, X., & Xiao, P. (2018). Pore filling behavior of YSZ under CMAS attack: Implications for designing corrosion-resistant thermal barrier coatings. Journal Of The American Ceramic Society , 101 , 5756–5770. https://doi.org/10.1111/jace.15790 Chen, Z., Hu, P., Pei, Y., Teng, J., Dong, T., Wang, J., Chen, M., Li, S., & Wang, F. (2023). Anti-CMAS corrosion mechanism of Al 2 O 3 pore sealing and laser remelting on thermal barrier coatings. Journal Of The European Ceramic Society , 43 , 1567–1578. https://doi.org/10.1016/j.jeurceramsoc.2022.11.031 Sun, S., Xue, Z., He, W., He, J., Li, Q., & Guo, H. (2019). Corrosion resistant plasma sprayed (Y 0.8 Gd 0.2 ) 3 Al 5 O 12 /YSZ thermal barrier coatings towards molten calcium-magnesium-alumina-silicate. Ceramic International , 45 , 8138–8144. https://doi.org/10.1016/j.ceramint.2019.01.114 Li, B., Chen, Z., Zheng, H., Li, G., Li, H., & Peng, P. (2019). Wetting mechanism of CMAS melt on YSZ surface at high temperature: First-principles calculation. Applied Surface Science , 483 , 811–818. https://doi.org/10.1016/j.apsusc.2019.04.009 Liu, Y., Zhang, W., Wang, W., Liu, W., Yang, T., Li, K., Tang, Z., Liu, C., & Zhang, C. (2024). Evolution of microstructure, thermophysical and mechanical properties and wetting behavior of plasma-sprayed Yb 2 O 3 and Y 2 O 3 co-stabilized ZrO 2 coatings during high-temperature exposure and CMAS corrosion. Surface & Coatings Technology , 477 , 130278. https://doi.org/10.1016/j.surfcoat.2023.130278 Yost, F. G., Rye, R. R., & Mann, J. A. (1997). Solder wetting kinetics in narrow V-grooves. Acta Materialia , 45 , 5337–5345. https://doi.org/10.1016/S1359-6454(97)00205-X Poerschke, D. L., Shaw, J. H., Verma, N., Zok, F. W., & Levi, C. G. (2018). Interaction of yttrium disilicate environmental barrier coatings with calcium-magnesium-iron alumino-silicate melts. Acta Materialia , 145 , 451–461. https://doi.org/10.1016/j.actamat.2017.12.004 Wang, T., Shao, F., Ni, J., Zhao, H., Zhuang, Y., Sheng, J., Zhong, X., Yang, J., Tao, S., & Yang, K. (2021). Calcium-magnesium-aluminum-silicate (CMAS) corrosion resistance of Y-Yb-Gd-stabilized zirconia thermal barrier coatings. Journal Of Thermal Spray Technology , 30 , 442–456. https://doi.org/10.1007/s11666-020-01142-2 Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 10 Jul, 2025 Reviewers invited by journal 13 May, 2025 Editor assigned by journal 12 May, 2025 First submitted to journal 07 May, 2025 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. 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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-6611295","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":455838128,"identity":"6864833a-4931-4022-abf4-cdb4003786e1","order_by":0,"name":"Na Xu","email":"","orcid":"","institution":"Institute of Metal Research Chinese Academy of Sciences","correspondingAuthor":false,"prefix":"","firstName":"Na","middleName":"","lastName":"Xu","suffix":""},{"id":455838129,"identity":"c25bcd41-d968-4415-8507-7b0f5b64a4a8","order_by":1,"name":"Yiqing Sui","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAABEklEQVRIiWNgGAWjYDACZgaGAyCajb2BgSGhACbMRowWHiCVYABTjU8LHEgkAAlitBgcZ954uOBXXWKf5OvEDw8MGBLnz29+wPCh7DAD/+wG7FoOsxUcntl3OLFNOnezBNBhiRuOsRkwzjh3mEHizgEcWngMDvP2HABp2QDRwsbDwMzbdpjBAOxUnFrqEtskz27+AdIyvw2o5S8hLTw/mBPbJHi3gW1pOAbUwohHiyTIL7wNh43beHK3WSQYSBhvOJZmcLDnXDqPxA3sWvjOH978medPnez89rObb/6osJGd33z44YMfZdZy/DOwa1E4AIwLxjY4XwJMHgBiHqzqgUC+ARR9f3BJj4JRMApGwSgAAgBETV/glUNsPAAAAABJRU5ErkJggg==","orcid":"https://orcid.org/0009-0008-3651-742X","institution":"University of Science and Technology","correspondingAuthor":true,"prefix":"","firstName":"Yiqing","middleName":"","lastName":"Sui","suffix":""},{"id":455838130,"identity":"a666e519-d693-44b4-bebf-c76f65ff14f7","order_by":2,"name":"Lanxin Zou","email":"","orcid":"","institution":"University of Science and Technology of China","correspondingAuthor":false,"prefix":"","firstName":"Lanxin","middleName":"","lastName":"Zou","suffix":""},{"id":455838131,"identity":"ca1a6161-5985-4315-bd5d-8a40a4f0d283","order_by":3,"name":"Shuang Qin","email":"","orcid":"","institution":"University of Science and Technology of China","correspondingAuthor":false,"prefix":"","firstName":"Shuang","middleName":"","lastName":"Qin","suffix":""},{"id":455838132,"identity":"b09092d2-7aff-40f1-99fa-dc0e7f681925","order_by":4,"name":"Minghao Gao","email":"","orcid":"","institution":"Institute of Metal Research Chinese Academy of Sciences","correspondingAuthor":false,"prefix":"","firstName":"Minghao","middleName":"","lastName":"Gao","suffix":""},{"id":455838133,"identity":"9fec0fd6-2dc1-45bc-9c43-6752884c639d","order_by":5,"name":"Xinchun Chang","email":"","orcid":"","institution":"Institute of Metal Research Chinese Academy of Sciences","correspondingAuthor":false,"prefix":"","firstName":"Xinchun","middleName":"","lastName":"Chang","suffix":""}],"badges":[],"createdAt":"2025-05-07 10:59:28","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-6611295/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-6611295/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":82811136,"identity":"dff08128-ac16-4121-bb51-c3eec8f5a18b","added_by":"auto","created_at":"2025-05-15 13:25:32","extension":"png","order_by":1,"title":"Figure 1","display":"","copyAsset":false,"role":"figure","size":6240582,"visible":true,"origin":"","legend":"\u003cp\u003e\u003cstrong\u003e(a)\u003c/strong\u003e Cross-sectional morphologies of the as-sprayed GYYSZ coatings\u003cstrong\u003e(b)\u003c/strong\u003e magnified views of area b in figure (a); \u003cstrong\u003ec\u003c/strong\u003e magnified views of area c in figure (a)\u003c/p\u003e","description":"","filename":"1.png","url":"https://assets-eu.researchsquare.com/files/rs-6611295/v1/248a21154edaf5e185ce1831.png"},{"id":82811235,"identity":"9cf7c45b-6809-4f33-8364-9200b7e4485c","added_by":"auto","created_at":"2025-05-15 13:25:45","extension":"png","order_by":2,"title":"Figure 2","display":"","copyAsset":false,"role":"figure","size":24405213,"visible":true,"origin":"","legend":"\u003cp\u003eSurface morphology information of GYYSZ coatings with different roughness:\u003cstrong\u003e (a)\u003c/strong\u003e surface SEM images \u003cstrong\u003e(b)\u003c/strong\u003e3D surface laser confocal images \u003cstrong\u003e(c)\u003c/strong\u003e line roughness profiles\u003c/p\u003e","description":"","filename":"2.png","url":"https://assets-eu.researchsquare.com/files/rs-6611295/v1/bfbe3d6fc31fae03528c5cb1.png"},{"id":82811138,"identity":"992b074a-133e-4ad6-b328-ab9360c954d4","added_by":"auto","created_at":"2025-05-15 13:25:32","extension":"png","order_by":3,"title":"Figure 3","display":"","copyAsset":false,"role":"figure","size":11668242,"visible":true,"origin":"","legend":"\u003cp\u003eCharacterization results of GYYSZ coatings with different roughness after CMAS wetting tests at 1250 °C for 30 min: \u003cstrong\u003e(a)\u003c/strong\u003e macro morphology \u003cstrong\u003e(b)\u003c/strong\u003ecross-sectional microstructures \u003cstrong\u003e(c)\u003c/strong\u003e surface micro morphology\u003c/p\u003e","description":"","filename":"3.png","url":"https://assets-eu.researchsquare.com/files/rs-6611295/v1/c4906dc3a27cfa8603231924.png"},{"id":82811745,"identity":"1e917af0-c15e-4bba-abb0-47a9106ec5ef","added_by":"auto","created_at":"2025-05-15 13:33:32","extension":"png","order_by":4,"title":"Figure 4","display":"","copyAsset":false,"role":"figure","size":2409455,"visible":true,"origin":"","legend":"\u003cp\u003eSpreading area of CMAS and contact angle between molten CMAS and GYYSZ coatings with different roughness after CMAS wetting for 30 min\u003c/p\u003e","description":"","filename":"4.png","url":"https://assets-eu.researchsquare.com/files/rs-6611295/v1/9874f54006f4324a7972a907.png"},{"id":82811747,"identity":"6800d1bb-b1a9-475b-82fb-880503d5bd31","added_by":"auto","created_at":"2025-05-15 13:33:32","extension":"png","order_by":5,"title":"Figure 5","display":"","copyAsset":false,"role":"figure","size":6389476,"visible":true,"origin":"","legend":"\u003cp\u003e\u003cstrong\u003e(a)\u003c/strong\u003e Cross-sectional microstructures of the as-sprayed GYYSZ coatings under CMAS exposure at 1250 °C for 1 h \u003cstrong\u003e(b)\u003c/strong\u003eis the magnified view of the corresponding area outlined in black frame in (a) \u003cstrong\u003e(c)\u003c/strong\u003eand \u003cstrong\u003e(d-f)\u003c/strong\u003e are magnified views of the corresponding areas outlined in black frames in (b) and (a), respectively\u003c/p\u003e","description":"","filename":"5.png","url":"https://assets-eu.researchsquare.com/files/rs-6611295/v1/69ef4af5bdbfefe94a80c4b4.png"},{"id":82811746,"identity":"9f2d9210-e1b8-4f32-be27-3eccfeb1dc12","added_by":"auto","created_at":"2025-05-15 13:33:32","extension":"png","order_by":6,"title":"Figure 6","display":"","copyAsset":false,"role":"figure","size":5765044,"visible":true,"origin":"","legend":"\u003cp\u003e\u003cstrong\u003e(a)\u003c/strong\u003e Cross-sectional microstructures of the as-sprayed GYYSZ coatings under CMAS exposure at 1250 °C for 5 h\u003cstrong\u003e (b-d)\u003c/strong\u003e are magnified views of the corresponding areas outlined in black frames in (a).\u003c/p\u003e","description":"","filename":"6.png","url":"https://assets-eu.researchsquare.com/files/rs-6611295/v1/c90384a8fbbdf2380a35d269.png"},{"id":82811141,"identity":"a93059ea-4f35-4fbb-aaef-92afedf15a5c","added_by":"auto","created_at":"2025-05-15 13:25:32","extension":"png","order_by":7,"title":"Figure 7","display":"","copyAsset":false,"role":"figure","size":6303629,"visible":true,"origin":"","legend":"\u003cp\u003e\u003cstrong\u003e(a)\u003c/strong\u003e Cross-sectional microstructures of the as-sprayed GYYSZ coatings under CMAS exposure at 1250 °C for 20 h \u003cstrong\u003e(b-d)\u003c/strong\u003eare magnified views of the corresponding areas outlined in black frames in (a).\u003c/p\u003e","description":"","filename":"7.png","url":"https://assets-eu.researchsquare.com/files/rs-6611295/v1/652a8ef2875e30a3b640f4dd.png"},{"id":82811170,"identity":"0146ee25-5687-4e98-9390-819d328c1076","added_by":"auto","created_at":"2025-05-15 13:25:35","extension":"png","order_by":8,"title":"Figure 8","display":"","copyAsset":false,"role":"figure","size":3479417,"visible":true,"origin":"","legend":"\u003cp\u003eXRD pattern of the as-sprayed GYYSZ coatings and GYYSZ coatings under CMAS exposure at 1250 °C for 1, 5 and 20 h\u003c/p\u003e","description":"","filename":"8.png","url":"https://assets-eu.researchsquare.com/files/rs-6611295/v1/cf2c0fbef658257c186a9942.png"},{"id":82811149,"identity":"c55fbf4e-644b-4999-90e5-169542499e5f","added_by":"auto","created_at":"2025-05-15 13:25:33","extension":"png","order_by":9,"title":"Figure 9","display":"","copyAsset":false,"role":"figure","size":23196548,"visible":true,"origin":"","legend":"\u003cp\u003eCross-sectional microstructures of GYYSZ coatings with different roughness exposed to CMAS for \u003cstrong\u003e(a)\u003c/strong\u003e5 h and\u003cstrong\u003e(b)\u003c/strong\u003e 20 h\u003c/p\u003e","description":"","filename":"9.png","url":"https://assets-eu.researchsquare.com/files/rs-6611295/v1/57ad5e52a04bb5ba39a9cb30.png"},{"id":82811142,"identity":"5ff60594-903c-40bd-ae37-a9aa4ff323e0","added_by":"auto","created_at":"2025-05-15 13:25:32","extension":"png","order_by":10,"title":"Figure 10","display":"","copyAsset":false,"role":"figure","size":7589234,"visible":true,"origin":"","legend":"\u003cp\u003eSurface morphologies of GYYSZ coatings with different roughness exposed to CMAS for 20 h\u003c/p\u003e","description":"","filename":"10.png","url":"https://assets-eu.researchsquare.com/files/rs-6611295/v1/228e2a7c34b8ea9d0bcf1371.png"},{"id":82811748,"identity":"7f088683-4ba3-4b90-90c4-fa66e33e1a72","added_by":"auto","created_at":"2025-05-15 13:33:32","extension":"png","order_by":11,"title":"Figure 11","display":"","copyAsset":false,"role":"figure","size":7875175,"visible":true,"origin":"","legend":"\u003cp\u003eSchematic diagram of CMAS corrosion of GYYSZ coatings: \u003cstrong\u003e(a)\u003c/strong\u003e as-sprayed coatings \u003cstrong\u003e(b)\u003c/strong\u003eground coatings\u003c/p\u003e","description":"","filename":"11.png","url":"https://assets-eu.researchsquare.com/files/rs-6611295/v1/10bd70038ea6ead66964a850.png"},{"id":82812913,"identity":"5373baa8-2621-42ab-8546-5db4315bd19c","added_by":"auto","created_at":"2025-05-15 13:50:25","extension":"pdf","order_by":0,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":101467494,"visible":true,"origin":"","legend":"","description":"","filename":"manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6611295/v1/e0a7dbea-8339-4263-b69c-4820b08f8708.pdf"}],"financialInterests":"","formattedTitle":"CMAS corrosion resistance of Gd2O3-Yb2O3-Y2O3-stabilized ZrO2 coatings with different surface states","fulltext":[{"header":"Introduction","content":"\u003cp\u003eThermal barrier coatings (TBCs) are a kind of relatively low-cost technology used in high-temperature components of aircraft engines to provide thermal insulation, consequently enabling the high-temperature components to operate at higher temperature [\u003cspan additionalcitationids=\"CR2\" citationid=\"CR1\" class=\"CitationRef\"\u003e1\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR3\" class=\"CitationRef\"\u003e3\u003c/span\u003e]. TBCs usually consist of bond coat and ceramic top coat [\u003cspan citationid=\"CR4\" class=\"CitationRef\"\u003e4\u003c/span\u003e]. YSZ is the most widely used ceramic top coat material because of its low thermal conductivity and thermal expansion coefficient closely matching that of the bond coat [\u003cspan additionalcitationids=\"CR6\" citationid=\"CR5\" class=\"CitationRef\"\u003e5\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR7\" class=\"CitationRef\"\u003e7\u003c/span\u003e]. Nevertheless, YSZ coatings are inevitably affected by atmospheric dust, volcanic ash and other particles under actual service conditions. The main components of these environmental particles are CaO, MgO, Al\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e, SiO\u003csub\u003e2\u003c/sub\u003e, referred to as CMAS [\u003cspan additionalcitationids=\"CR9\" citationid=\"CR8\" class=\"CitationRef\"\u003e8\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR10\" class=\"CitationRef\"\u003e10\u003c/span\u003e]. CMAS that adheres to the surface of YSZ melts at high temperatures, penetrates into the coatings through defects, causes phase transformations and reduces the porosity, thermal insulation, and strain tolerance [\u003cspan additionalcitationids=\"CR12\" citationid=\"CR11\" class=\"CitationRef\"\u003e11\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR13\" class=\"CitationRef\"\u003e13\u003c/span\u003e]. This corrosive process will accelerate spallation of coatings and ultimately lead to the failure of TBCs.\u003c/p\u003e \u003cp\u003eImproving the CMAS corrosion resistance of coatings has become a research focus in the field of TBCs [\u003cspan additionalcitationids=\"CR15\" citationid=\"CR14\" class=\"CitationRef\"\u003e14\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR16\" class=\"CitationRef\"\u003e16\u003c/span\u003e]. Doping and modifying conventional YSZ [\u003cspan additionalcitationids=\"CR18\" citationid=\"CR17\" class=\"CitationRef\"\u003e17\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR19\" class=\"CitationRef\"\u003e19\u003c/span\u003e] are common strategies to enhance the CMAS corrosion resistance of TBCs in addition to developing novel TBCs materials such as rare earth zirconates (RE\u003csub\u003e2\u003c/sub\u003eZr\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e7\u003c/sub\u003e) [\u003cspan additionalcitationids=\"CR21\" citationid=\"CR20\" class=\"CitationRef\"\u003e20\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR22\" class=\"CitationRef\"\u003e22\u003c/span\u003e] and rare earth phosphates (REPO\u003csub\u003e4\u003c/sub\u003e) [\u003cspan citationid=\"CR23\" class=\"CitationRef\"\u003e23\u003c/span\u003e, \u003cspan citationid=\"CR24\" class=\"CitationRef\"\u003e24\u003c/span\u003e]. Guo et al. [\u003cspan citationid=\"CR25\" class=\"CitationRef\"\u003e25\u003c/span\u003e] synthesized RE₂O₃-Yb₂O₃ co-doped YSZ (REYb-YSZ, RE\u0026thinsp;=\u0026thinsp;La, Nd, Gd) ceramics materials, which exhibited superior high-temperature phase stability and lower thermal conductivity than YSZ. Su et al. [\u003cspan citationid=\"CR26\" class=\"CitationRef\"\u003e26\u003c/span\u003e] conducted first-principles calculations and CMAS corrosion experiments on YSZ, Gd\u003csub\u003e2\u003c/sub\u003eZr\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e7\u003c/sub\u003e and YSZ(Gd) to investigate how Gd element influences the CMAS corrosion behavior of zirconium-based coatings at high temperature. The results indicate that the existence of the Gd element decreases the diffusion coefficients of the Y, Zr and O elements, and the corrosion depth of Gd\u003csub\u003e2\u003c/sub\u003eZr\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e7\u003c/sub\u003e and GdYSZ is lower than that of YSZ. It can be inferred that Gd element is beneficial to enhance the corrosion resistance of YSZ coatings under CMAS condition. Fang et al. [\u003cspan citationid=\"CR27\" class=\"CitationRef\"\u003e27\u003c/span\u003e] investigated the corrosion behavior of YSZ and YbYSZ under CMAS conditions using first-principles calculations and corrosion experiments. The results represent that YbYSZ has better corrosion resistance than YSZ under the condition of CMAS, which may be because the diffusion coefficient of Yb\u003csup\u003e3+\u003c/sup\u003e is lower than Y\u003csup\u003e3+\u003c/sup\u003e. Consequently, doping YSZ with Yb\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e can increase its resistance against CMAS corrosion. Bahamirian et al. [\u003cspan citationid=\"CR28\" class=\"CitationRef\"\u003e28\u003c/span\u003e] confirmed that 5.2Gd\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-5.6Yb\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-9.5Y\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-ZrO\u003csub\u003e2\u003c/sub\u003e powder maintains exceptional phase stability after 50 h at 1300\u0026deg;C, highlighting its potential for TBCs applications. However, its CMAS corrosion resistance remains understudied.\u003c/p\u003e \u003cp\u003eMany researchers have reported that optimizing the surface morphology of coatings can improve the CMAS corrosion resistance. Yan et al. [\u003cspan citationid=\"CR29\" class=\"CitationRef\"\u003e29\u003c/span\u003e] demonstrated that TBCs after laser-glazed treatment exhibit smooth surface and dense microstructure. Hence, the laser-modified coatings exhibited stronger resistance to CMAS corrosion compared to the as-sprayed coatings. Wang et al. [\u003cspan citationid=\"CR30\" class=\"CitationRef\"\u003e30\u003c/span\u003e] reported that the coatings with micro-nano double scale structures prepared by solution precursor plasma spray (SPPS) could help reduce CMAS wettability on the coatings and accordingly enhance corrosion resistance under CMAS exposure. Guo et al. [\u003cspan citationid=\"CR31\" class=\"CitationRef\"\u003e31\u003c/span\u003e] revealed the polished bulk materials exhibit better CMAS wetting resistance than the as-fabricated bulks, concluding that reduced surface roughness improves CMAS resistance. The critical role of coatings surface roughness on the wetting behavior of CMAS was also highlighted by Yang et al. [\u003cspan citationid=\"CR32\" class=\"CitationRef\"\u003e32\u003c/span\u003e] and Yin et al. [\u003cspan citationid=\"CR33\" class=\"CitationRef\"\u003e33\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eIn order to explore the interaction mechanism between CMAS and 5.2Gd\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-5.6Yb\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-9.5Y\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-ZrO\u003csub\u003e2\u003c/sub\u003e (GYYSZ) coatings with different surface states, this study focused on three groups of atmospheric plasma spray (APS) GYYSZ coatings with varying surface roughness. The surface characteristics of one group of as-sprayed coatings and two groups of polished coatings were compared, and the wetting behavior and corrosion mechanism of GYYSZ coatings under CMAS exposure at 1250\u0026deg;C were investigated.\u003c/p\u003e"},{"header":"Materials and methods","content":"\u003cdiv id=\"Sec3\" class=\"Section2\"\u003e \u003ch2\u003e2.1 Preparation of coatings\u003c/h2\u003e \u003cp\u003eThe composition and granularity of the GYYSZ powder used in this study were 5.2Gd\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-5.6Yb\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-9.5Y\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-ZrO\u003csub\u003e2\u003c/sub\u003e (in wt%) and 30\u0026ndash;74 \u0026micro;m, respectively. The preparation of GYYSZ coatings by atmospheric plasma spraying is a complex process. The voltage and arc current were 70 V and 590 A, respectively. The flow of primary plasma gas (Ar) and secondary plasma gas (H\u003csub\u003e2\u003c/sub\u003e) were 38 slpm and 1.8 slpm. The spray distance was 90 mm, and the powder-feeding rate was 27 g\u0026middot;min\u003csup\u003e\u0026minus;\u0026thinsp;1\u003c/sup\u003e. A pause of 1 min is necessary after every 3 passes by thermal spray gun to prevent the formation of large cracks in the coatings during the spraying process. It is easy to separate the coatings from the graphite substrates when the thickness of the deposited coatings is enough due to the significant difference in the coefficient of thermal expansion between graphite and GYYSZ.\u003c/p\u003e \u003cp\u003eThe coatings with different surface roughness were prepared by sandpaper. The original sprayed coatings without any treatment are named As-sprayed group. The other two groups, ground with 120#, 240#, and 320# sandpaper, are designated as the Rough grinding group and Fine grinding group. The 2D surface roughness (Ra) of the coatings was tested by the SJ-210 surface roughness meter (Mitutoyo, Kawasaki, Japan), and the specific data are listed in Table\u0026nbsp;\u003cspan refid=\"Tab1\" class=\"InternalRef\"\u003e1\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab1\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 1\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eSurface roughness values of three groups of GYYSZ coatings\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eAs-sprayed\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eRough grinding\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eFine grinding\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003eRa (\u0026micro;m)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e6.42\u0026ndash;7.21\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e1.46\u0026ndash;1.72\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003e0.56\u0026ndash;0.75\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e\n\u003ch3\u003e2.2 Preparation of CMAS powder\u003c/h3\u003e\n\u003cp\u003eThe CMAS used in this study, composed of 33CaO-9MgO-13AlO\u003csub\u003e1.5\u003c/sub\u003e-45SiO\u003csub\u003e2\u003c/sub\u003e (mol%), was similar to the environmental deposits accumulated on the turbine shaft of aircraft operating in desert environments, as reported by Borom et al. [\u003cspan citationid=\"CR34\" class=\"CitationRef\"\u003e34\u003c/span\u003e]. Firstly, the weighed powders, zirconia balls and anhydrous ethanol were placed in a ceramic jar in a mass ratio of 1:2:1, respectively. Then the ceramic jar was put into the high-speed ball mill and run for 20 h. The obtained slurry was dried at 120\u0026deg;C for 6 h and then sintered at 1150\u0026deg;C for 24 h. Subsequent to ball milling and another drying process, the powder was further ground with a mortar and pestle to produce the final CMAS powder.\u003c/p\u003e\n\u003ch3\u003e2.3 Wetting and corrosion tests\u003c/h3\u003e\n\u003cp\u003eThe CMAS powder was pressed and cut into small pieces with the size of 3 \u0026times; 3 \u0026times; 1 mm. After the CMAS pieces were placed on the coating surfaces, the coatings were transferred to the furnace and held at 1250\u0026deg;C for 30 min. The coatings prepared for corrosion tests were coated with 20 mg\u0026middot;cm\u003csup\u003e\u0026minus;\u0026thinsp;2\u003c/sup\u003e of CMAS and then put into the furnace and subjected to heat treatment at 1250\u0026deg;C for 1, 5 and 20 h, respectively.\u003c/p\u003e\n\u003ch3\u003e2.4 Characterization\u003c/h3\u003e\n\u003cp\u003eThe environmental scanning electron microscope (SEM, Quattro S, FEI, Eindhoven, The Netherlands) was employed to gather information about the cross-sectional and surface morphology as well as the chemical composition of GYYSZ coatings. The laser confocal microscope (LSM 700, Zeiss, Jena, Germany) was used to obtain 3D surface morphology, line roughness profiles, and the associated surface roughness values of the coatings prior to the tests. The X-ray diffractometer (XRD, SmartLab, Rigaku, Tokyo, Japan) was applied to characterize the phase composition of the as-sprayed coatings and corroded coatings. The spreading diameters of CMAS on the coatings and the contact angles of molten CMAS on the coating surfaces were measured by ImageJ 1.8.0.\u003c/p\u003e"},{"header":"Results and discussion","content":"\u003cp\u003eFigure\u0026nbsp;\u003cspan refid=\"Fig1\" class=\"InternalRef\"\u003e1\u003c/span\u003e are SEM images about cross-sectional morphologies of the as-sprayed GYYSZ coatings. In Fig.\u0026nbsp;\u003cspan refid=\"Fig1\" class=\"InternalRef\"\u003e1\u003c/span\u003e(b), many V-grooves are observed in the cross-sectional profile, resulting in an unsmooth coating surface morphology. Microcracks and pores can be found in the as-sprayed coating as shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig1\" class=\"InternalRef\"\u003e1\u003c/span\u003e(c). It is primarily attributed to inadequate interparticle overlap and incorporated air during the spraying process [\u003cspan citationid=\"CR35\" class=\"CitationRef\"\u003e35\u003c/span\u003e]. Although it can help enhance the thermal insulation properties of TBCs, it also creates channels for CMAS penetration [\u003cspan additionalcitationids=\"CR37 CR38\" citationid=\"CR36\" class=\"CitationRef\"\u003e36\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR39\" class=\"CitationRef\"\u003e39\u003c/span\u003e]. EDS results of Point 1 in Fig.\u0026nbsp;\u003cspan refid=\"Fig1\" class=\"InternalRef\"\u003e1\u003c/span\u003e(a), as listed in Table\u0026nbsp;\u003cspan refid=\"Tab2\" class=\"InternalRef\"\u003e2\u003c/span\u003e, reveal that the composition of GYYSZ coatings is similar to that of GYYSZ powder, confirming the rationality of the selected spraying parameters.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab2\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 2\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eEDS results of the Points 1\u0026ndash;5 in Figs.\u0026nbsp;\u003cspan refid=\"Fig1\" class=\"InternalRef\"\u003e1\u003c/span\u003e, \u003cspan refid=\"Fig5\" class=\"InternalRef\"\u003e5\u003c/span\u003e, \u003cspan refid=\"Fig6\" class=\"InternalRef\"\u003e6\u003c/span\u003e and \u003cspan refid=\"Fig7\" class=\"InternalRef\"\u003e7\u003c/span\u003e (in wt%)\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"10\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c5\" colnum=\"5\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c6\" colnum=\"6\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c7\" colnum=\"7\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c8\" colnum=\"8\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c9\" colnum=\"9\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c10\" colnum=\"10\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eO\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eGd\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eYb\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c5\"\u003e \u003cp\u003eY\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c6\"\u003e \u003cp\u003eZr\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c7\"\u003e \u003cp\u003eCa\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c8\"\u003e \u003cp\u003eMg\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c9\"\u003e \u003cp\u003eAl\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c10\"\u003e \u003cp\u003eSi\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e1\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e20.76\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e5.1\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e6.03\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e \u003cp\u003e9.1\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c6\"\u003e \u003cp\u003e59.01\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c7\"\u003e \u003cp\u003e-\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c8\"\u003e \u003cp\u003e-\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c9\"\u003e \u003cp\u003e-\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c10\"\u003e \u003cp\u003e-\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e2\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e41.33\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e1.61\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e1.04\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e \u003cp\u003e1.54\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c6\"\u003e \u003cp\u003e4.2\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c7\"\u003e \u003cp\u003e21.57\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c8\"\u003e \u003cp\u003e3.15\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c9\"\u003e \u003cp\u003e6.45\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c10\"\u003e \u003cp\u003e19.11\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e3\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e22.19\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e5.6\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e5.23\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e \u003cp\u003e8.65\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c6\"\u003e \u003cp\u003e56.16\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c7\"\u003e \u003cp\u003e0.65\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c8\"\u003e \u003cp\u003e0.23\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c9\"\u003e \u003cp\u003e0.34\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c10\"\u003e \u003cp\u003e0.95\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e4\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e22.67\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e5.07\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e5.34\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e \u003cp\u003e8.28\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c6\"\u003e \u003cp\u003e55.87\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c7\"\u003e \u003cp\u003e1.21\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c8\"\u003e \u003cp\u003e0.27\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c9\"\u003e \u003cp\u003e0.28\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c10\"\u003e \u003cp\u003e1.01\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e5\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e23.23\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e4.51\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e5.24\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c5\"\u003e \u003cp\u003e8.35\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c6\"\u003e \u003cp\u003e55.39\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c7\"\u003e \u003cp\u003e1.38\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c8\"\u003e \u003cp\u003e0.31\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c9\"\u003e \u003cp\u003e0.36\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c10\"\u003e \u003cp\u003e1.23\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003cp\u003eSurface morphology information of GYYSZ coatings with three different roughness is shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig2\" class=\"InternalRef\"\u003e2\u003c/span\u003e. The uneven surface morphology of the as-sprayed coatings is shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig2\" class=\"InternalRef\"\u003e2\u003c/span\u003e(a), which is due to the plasma spraying process. Notably, the surface has both rough and smooth regions. The rough regions are related to semi-melted and unmelted particles, while the smooth regions are related to melted particles [\u003cspan citationid=\"CR40\" class=\"CitationRef\"\u003e40\u003c/span\u003e]. These particles are continuously stacked on the substrate to form coatings. The surface morphology in Fig.\u0026nbsp;\u003cspan refid=\"Fig2\" class=\"InternalRef\"\u003e2\u003c/span\u003e(a) and the 3D surface laser confocal images in Fig.\u0026nbsp;\u003cspan refid=\"Fig2\" class=\"InternalRef\"\u003e2\u003c/span\u003e(b) both indicates that the depth of V-grooves on the surface of GYYSZ decreases with the decrease of the surface roughness of the coating. The removal of some shallow V-grooves and the persistence of some deep V-grooves on the coating surfaces are due to the preferential contact of the sandpaper with the raised portions of the coatings. The related line roughness profiles are shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig2\" class=\"InternalRef\"\u003e2\u003c/span\u003e(c). It can be found that the vales of 3D surface roughness parameter (Sa) and 2D surface roughness parameter of GYYSZ coatings are similar to the average values of the initially measured roughness shown in Table\u0026nbsp;\u003cspan refid=\"Tab1\" class=\"InternalRef\"\u003e1\u003c/span\u003e. This consistency ensures the accuracy of the surface roughness measurements.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eIt has been demonstrated that the contact angle between molten CMAS and the coating, and the spreading area of CMAS can be used as evaluation indices for assessing the corrosion resistance of the coatings under CMAS exposure [\u003cspan citationid=\"CR41\" class=\"CitationRef\"\u003e41\u003c/span\u003e, \u003cspan citationid=\"CR42\" class=\"CitationRef\"\u003e42\u003c/span\u003e]. A larger contact angle and a smaller spreading area mean superior CMAS wetting resistance [\u003cspan citationid=\"CR31\" class=\"CitationRef\"\u003e31\u003c/span\u003e]. Characterization results of GYYSZ coatings with three different roughness after CMAS wetting tests at 1250\u0026deg;C for 30 min are shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig3\" class=\"InternalRef\"\u003e3\u003c/span\u003e. The spread of melted CMAS on the surface of the coating can be observed in Fig.\u0026nbsp;\u003cspan refid=\"Fig3\" class=\"InternalRef\"\u003e3\u003c/span\u003e(a), where the black dashed line represents the spread outer edge of molten CMAS. Figure\u0026nbsp;\u003cspan refid=\"Fig3\" class=\"InternalRef\"\u003e3\u003c/span\u003e(b) clearly illustrates that the contact angle of molten CMAS and GYYSZ coatings with different surface roughness are also different. Figure\u0026nbsp;\u003cspan refid=\"Fig3\" class=\"InternalRef\"\u003e3\u003c/span\u003e(c) shows the surface microstructure of the coatings after wetting experiment. The yellow dotted line represents the CMAS diffusion front, the dark area corresponds to CMAS, and the bright area represents GYYSZ coatings. It can be observed that CMAS at the spreading fronts exhibits low content and a discontinuous distribution, mainly in the V-grooves. It indicates the preferential flow of molten CMAS along the V-grooves. The experimental results shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig3\" class=\"InternalRef\"\u003e3\u003c/span\u003e are summarized in Fig.\u0026nbsp;\u003cspan refid=\"Fig4\" class=\"InternalRef\"\u003e4\u003c/span\u003e. It is not difficult to find that with the decrease of surface roughness, the diffusion area of molten CMAS also decreases, and the contact angle between molten CMAS and the coatings increases. This suggests that coatings with shallow V-grooves are more difficult to wet by CMAS than coatings with deep V-grooves.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eThe V-grooves structures on the solid surfaces are beneficial to improving the capillary force driving the spreading of liquid, as demonstrated by Yost et al. [\u003cspan citationid=\"CR43\" class=\"CitationRef\"\u003e43\u003c/span\u003e]. It showed that there is an increase in capillary force with increasing V-grooves depth. In other words, coatings with smaller surface V-grooves depth result in smaller capillary forces driving CMAS flow, leading to poorer flow ability of CMAS on shallow V-grooves compared to deep V-grooves. In addition to capillary action, the greater continuity of interconnection between V-grooves on the coating surfaces may make it easier for CMAS to spread outward. In contrast to the as-sprayed coating, the ground coatings exhibit smaller V-grooves depth and greater discontinuity in the interconnections between V-grooves. The driving force and the pathway for molten CMAS to spreading continuously are both diminished by the reduced V-grooves depth and continuity of interconnection between V-grooves, resulting in a superior CMAS wetting resistance of the ground coatings. The wetting behavior of CMAS on coatings is related to the surface microstructure of the coatings. Consequently, it is possible to strategically modify the surface microstructure of the coatings, aiming to minimize the wetting of CMAS to TBCs, accordingly mitigating the damage caused by CMAS in the coatings.\u003c/p\u003e \u003cp\u003eCross-sectional microstructures of the as-sprayed GYYSZ coatings without any treatment under CMAS exposure at 1250\u0026deg;C for 1, 5 and 20 h are shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig5\" class=\"InternalRef\"\u003e5\u003c/span\u003e\u0026ndash;\u003cspan refid=\"Fig7\" class=\"InternalRef\"\u003e7\u003c/span\u003e, respectively. It is clear that spherical particles form in GYYSZ coatings after CMAS exposure at 1250\u0026deg;C for 1\u0026ndash;20 h. Voids are observed in the residual CMAS layers as shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig6\" class=\"InternalRef\"\u003e6\u003c/span\u003e(b), possibly resulting from trapped gases within the coating escaping outward and being confined by CMAS [\u003cspan citationid=\"CR44\" class=\"CitationRef\"\u003e44\u003c/span\u003e]. Several key trends can be found in the corroded GYYSZ coatings with the extension of corrosion time. Firstly, there is a thickness reduction in residual CMAS on the coating surfaces, indicating the gradual infiltration of CMAS into the coatings. Secondly, the number of spherical particles in CMAS increases, and the quantity and size of spherical particles in the coating also increase significantly. This may be due to the prolonged interaction time between the coating and CMAS, as well as the growth of grain boundaries. Thirdly, the number of the voids observed in the residual CMAS layers increases with the extension of corrosion time, indicating the coatings continue to dissolve under CMAS exposure, resulting in more gas escaping from the pores in the coatings. Additionally, the sphericalization is not observed in the regions beneath the black dotted line (Fig.\u0026nbsp;\u003cspan refid=\"Fig5\" class=\"InternalRef\"\u003e5\u003c/span\u003e(a)) in the coating corroded for 1 h. However, the sphericalization occurred at the bottom of the coatings after 5 h and 20 h of CMAS corrosion, as shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig6\" class=\"InternalRef\"\u003e6\u003c/span\u003e and Fig.\u0026nbsp;\u003cspan refid=\"Fig7\" class=\"InternalRef\"\u003e7\u003c/span\u003e. This indicates a continuous increase in CMAS penetration depth into the coatings. GYYSZ coating is fully penetrated by CMAS after only 5 h of corrosion.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eThe size of the spherical particles observed in the interior of GYYSZ coatings (Fig.\u0026nbsp;\u003cspan refid=\"Fig5\" class=\"InternalRef\"\u003e5\u003c/span\u003e(d), Fig.\u0026nbsp;\u003cspan refid=\"Fig6\" class=\"InternalRef\"\u003e6\u003c/span\u003e(c) and Fig.\u0026nbsp;\u003cspan refid=\"Fig7\" class=\"InternalRef\"\u003e7\u003c/span\u003e(c)) is smaller than that on the surfaces of GYYSZ coatings (Fig.\u0026nbsp;\u003cspan refid=\"Fig5\" class=\"InternalRef\"\u003e5\u003c/span\u003e(c), Fig.\u0026nbsp;\u003cspan refid=\"Fig6\" class=\"InternalRef\"\u003e6\u003c/span\u003e(b) and Fig.\u0026nbsp;\u003cspan refid=\"Fig7\" class=\"InternalRef\"\u003e7\u003c/span\u003e(b)). This may be related to the order of reactions between the coatings and CMAS, where the coating surface react with CMAS before the interior of the coatings [\u003cspan citationid=\"CR45\" class=\"CitationRef\"\u003e45\u003c/span\u003e]. EDS results of the Points 2\u0026ndash;5 observed in Fig.\u0026nbsp;\u003cspan refid=\"Fig5\" class=\"InternalRef\"\u003e5\u003c/span\u003e\u0026ndash;\u003cspan refid=\"Fig7\" class=\"InternalRef\"\u003e7\u003c/span\u003e are shown in Table\u0026nbsp;\u003cspan refid=\"Tab2\" class=\"InternalRef\"\u003e2\u003c/span\u003e. Point 2 is a random point within the CMAS region. However, the presence of rare earth and Zr elements is detected at this point through EDS analysis, indicating that coating elements can diffuse outward. It can be clearly seen from Table\u0026nbsp;\u003cspan refid=\"Tab2\" class=\"InternalRef\"\u003e2\u003c/span\u003e that the contents of rare earth elements and zirconium elements is higher than that of Ca, Mg, Al, and Si in Points 3\u0026ndash;5. There is a significant difference in the content of compared to the element content at Point 2. It can be inferred that the spherical particles are the result of coating elements dissolving under the influence of CMAS, then diffusing into the CMAS and re-precipitating. Combined with the XRD data in Fig.\u0026nbsp;\u003cspan refid=\"Fig8\" class=\"InternalRef\"\u003e8\u003c/span\u003e, it can be speculated that the phase composition of the spherical particles is c-ZrO\u003csub\u003e2\u003c/sub\u003e. In addition, spherical particles are also observed inside the coatings, indicating that CMAS has diffused deep into the GYYSZ coatings. It also induces the dissolution and re-precipitation of rare earth elements and zirconium elements, resulting in the formation of spherical particles in the coatings similar to those in CMAS. Besides, Fig.\u0026nbsp;\u003cspan refid=\"Fig8\" class=\"InternalRef\"\u003e8\u003c/span\u003e also shows that the coatings maintain cubic zirconia phase after corrosion in CMAS for 1, 5, and 20 hours, indicating excellent phase stability of GYYSZ coatings.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eCMAS corrosion tests are conducted on the as-sprayed and ground GYYSZ coatings to assess the CMAS corrosion resistance of the coatings with different surface states. Figure\u0026nbsp;\u003cspan refid=\"Fig9\" class=\"InternalRef\"\u003e9\u003c/span\u003e is cross-sectional microstructures of GYYSZ coatings with different roughness exposed to CMAS for 5 h and 20 h. Figure\u0026nbsp;\u003cspan refid=\"Fig10\" class=\"InternalRef\"\u003e10\u003c/span\u003e is surface morphologies of GYYSZ coatings with different roughness exposed to CMAS for 20 h. Two distinct layers are visible in the cross-sectional microstructures: the residual CMAS layer on the coatings surface and the underlying GYYSZ coatings. Spherical particles can be observed in the residual CMAS layer. This phenomenon is a result of the continuous dissolution and diffusion of rare earth elements from the coating into the CMAS, followed by their reprecipitation within the CMAS. Among the three groups of GYYSZ coatings, the residual CMAS content on the coating surface of Fine grinding was the highest, and the distribution density of spherical particles in residual CMAS was the lowest. This difference may be due to the different surface microstructure of the coating (as shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig2\" class=\"InternalRef\"\u003e2\u003c/span\u003e). The overall distribution density of V-grooves on the coatings decreased after grinding the coatings surface, leading to a decrease in the specific surface area. This reduction results in a smaller area of the coatings interacting with CMAS, which weakens the reaction between the coatings and molten CMAS. Therefore, the dissolution rate of the coatings under CMAS exposure is reduced, and the formation of spherical particles is reduced. It can be inferred that grinding the coatings by sandpaper to reduce the distribution of V-grooves is beneficial for improving the corrosion resistance of the coatings to CMAS. A fewer V-grooves on the coating surfaces leads to a lower reactivity between the coatings and CMAS. In this study, the surface roughness of the coatings is positively correlated with the distribution of V-grooves on their surface. Thus, the corrosion resistance of the coatings to CMAS can be enhanced by decreasing the surface roughness of the coatings.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eFigure\u0026nbsp;\u003cspan refid=\"Fig11\" class=\"InternalRef\"\u003e11\u003c/span\u003e is a schematic diagram of CMAS corrosion of GYYSZ coatings in the as-sprayed and ground states. Figure\u0026nbsp;\u003cspan refid=\"Fig11\" class=\"InternalRef\"\u003e11\u003c/span\u003e(a) represents the initial state of interaction between as-sprayed GYYSZ coatings surface without polishing treatment and CMAS. There are pores and micro-cracks inside the coatings, and a large number of V-grooves on the surface of the as-sprayed coatings. These defects provide channels and reaction sites for CMAS attack. Figure\u0026nbsp;\u003cspan refid=\"Fig11\" class=\"InternalRef\"\u003e11\u003c/span\u003e(b) shows that the molten CMAS completely spreads over the surface of the as-sprayed coatings and thoroughly wets the coatings. There will be interdiffusion of elements between coatings and CMAS. The Ca, Mg, Al, Si from CMAS penetrate into the coatings and induce a \"dissolution-reprecipitation\" reaction in the GYYSZ coatings, causing the formation of spherical particles in coatings. Some of the dissolved RE and zirconium elements diffuse into the CMAS and re-precipitate, leading to the formation of spherical particles within the CMAS as well. The spherical ZrO\u003csub\u003e2\u003c/sub\u003e particles are first formed near the interface between the corrosive medium and the coatings, as these regions are the initial zone of mutual diffusion. The structural integrity of the coatings gradually degraded with the further penetration of CMAS into the coatings, resulting in the release of gas originally wrapped in the coatings. Some of gases fail to escape in time and are retained during the cooling and solidification process of CMAS, thus forming pores in CMAS. It can be seen in Fig.\u0026nbsp;\u003cspan refid=\"Fig11\" class=\"InternalRef\"\u003e11\u003c/span\u003e(c) that CMAS has deeply penetrated the coatings, the structure of the coatings has been damaged more seriously, and the diffusion of elements continues. The number of spherical ZrO\u003csub\u003e2\u003c/sub\u003e particles increased, as did the number and size of pores in CMAS. This implies that the interaction between CMAS and the coatings is intensified with the corrosion process, and the performance of the coatings deteriorates gradually. Figure\u0026nbsp;\u003cspan refid=\"Fig11\" class=\"InternalRef\"\u003e11\u003c/span\u003e(d) demonstrates the initial state of interaction between the surface of the ground GYYSZ coating and CMAS. The surface of ground coatings is relatively flat, with small undulations and sparse distribution of V-grooves. The initially molten CMAS cannot immediately spread over the entire coating surface because of the smooth coatings surface, and there is a certain contact angle between CMAS and coatings, as shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig11\" class=\"InternalRef\"\u003e11\u003c/span\u003e(e). The smooth surface will also reduce the contact area between CMAS and coatings, incurring a slower infiltration of CMAS and reaction rate between CMAS and the coatings, and weaker initial interaction. Therefore, no obvious spherical ZrO\u003csub\u003e2\u003c/sub\u003e particles or numerous pores have formed yet. Figure\u0026nbsp;\u003cspan refid=\"Fig11\" class=\"InternalRef\"\u003e11\u003c/span\u003e(f) reveals that although the ground coatings exhibit lower reactivity with CMAS, prolonged corrosion not only increases the number of spherical ZrO\u003csub\u003e2\u003c/sub\u003e particles in the coatings and CMAS, but also causes more gas to be trapped within the CMAS. However, fewer spherical particles and pores are formed compared to the as-sprayed coatings. It can be observed that there are more residual CMAS on the ground coatings surface (as shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig9\" class=\"InternalRef\"\u003e9\u003c/span\u003e), indicating less CMAS infiltration into the coatings. The number of spherical particles formed on the surface of as-sprayed coatings is greater than that of ground coatings, which can be observed in Fig.\u0026nbsp;\u003cspan refid=\"Fig10\" class=\"InternalRef\"\u003e10\u003c/span\u003e, implying that the as-sprayed coatings experience more elemental loss. Consequently, the CMAS corrosion resistance of the ground coatings is superior to the that of as-sprayed coatings.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e"},{"header":"Conclusions","content":"\u003cp\u003eGYYSZ coatings with different surface states were prepared by mechanical grinding. The wetting and corrosion behaviors of these coatings were systematically investigated and compared under CMAS corrosion. Results indicate that CMAS exhibits a reduced diffusion area on the mechanically ground GYYSZ coatings surface, along with an increased contact angle between molten CMAS and the coatings compared to the a-sprayed coatings. It was turned out that ground coatings possess better resistance to CMAS wettability. Lower surface roughness correlates with improved resistance to CMAS wettability, which attributed to the depth and density of V-grooves on the coating surface. The coating structure is damaged under the corrosion condition of CMAS at 1250\u0026deg;C. Due to the interdiffusion of elements between CMAS and GYYSZ coatings, the \"dissolution-reprecipitation\" reaction occurred in CMAS and coatings and spherical ZrO\u003csub\u003e2\u003c/sub\u003e particles were formed in the coatings and CMAS. In comparison to as-sprayed coatings, the ground coatings demonstrate more residual CMAS on the surface and fewer spherical particles. Notably, GYYSZ maintains the cubic zirconia phase after 20 h of exposure to CMAS at 1250\u0026deg;C, exhibiting excellent phase stability. These findings substantiate that reducing surface roughness enhances the corrosion resistance of GYYSZ coatings against CMAS, providing valuable insights into the corrosion mechanism of CMAS on multi-rare earth oxide-stabilized zirconia TBCs.\u003c/p\u003e"},{"header":"Declarations","content":"\u003cp\u003e \u003cstrong\u003eConflict of Interest\u003c/strong\u003e \u003cp\u003eThe authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.\u003c/p\u003e \u003c/p\u003e\u003cp\u003e \u003ch2\u003eEthical approval\u003c/h2\u003e \u003cp\u003eNot applicable\u003c/p\u003e \u003c/p\u003e\u003ch2\u003eAuthor contributions\u003c/h2\u003e \u003cp\u003eNa Xu: original draft, conceptualization, methodology, validation, supervision and funding acquisition. Yiqing Sui: investigation, writing, review, editing, formal analysis, visualization and conceptualization. Lanxin Zou: investigation, writing, editing, visualization and formal analysis. Shuang Qin: formal analysis and review. Minghao Gao: methodology, supervision and formal analysis. Xinchun Chang: funding acquisition.\u003c/p\u003e\u003ch2\u003eAcknowledgements\u003c/h2\u003e \u003cp\u003eThe authors gratefully acknowledge the financial support from GFang Basic Research Program Funds (JCKY2021204A004).\u003c/p\u003e\u003ch2\u003eData availability\u003c/h2\u003e \u003cp\u003eAll datasets generated or analyzed during the current study are described as presented figures or tables. The data used in this study are available upon request.\u003c/p\u003e"},{"header":"References","content":"\u003col\u003e\u003cli\u003e\u003cspan\u003eVa\u0026szlig;en, R., Jarligo, M. O., Steinke, T., Mack, D. E., \u0026amp; St\u0026ouml;ever, D. (2010). 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Calcium-magnesium-aluminum-silicate (CMAS) corrosion resistance of Y-Yb-Gd-stabilized zirconia thermal barrier coatings. \u003cem\u003eJournal Of Thermal Spray Technology\u003c/em\u003e, \u003cem\u003e30\u003c/em\u003e, 442\u0026ndash;456. \u003cspan class=\"ExternalRef\"\u003e\u003cspan class=\"RefSource\"\u003ehttps://doi.org/10.1007/s11666-020-01142-2\u003c/span\u003e\u003cspan address=\"10.1007/s11666-020-01142-2\" targettype=\"DOI\" class=\"RefTarget\"\u003e\u003c/span\u003e\u003c/span\u003e\u003c/span\u003e\u003c/li\u003e\u003c/ol\u003e"}],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":true,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":false,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":false,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"international-journal-of-mechanical-and-materials-engineering","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"ijme","sideBox":"Learn more about [International Journal of Mechanical and Materials Engineering](http://ijmme.springeropen.com)","snPcode":"40712","submissionUrl":"https://www.editorialmanager.com/ijme/default2.aspx","title":"International Journal of Mechanical and Materials Engineering","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Open","inReviewEnabled":true,"inReviewRevisionsEnabled":true},"keywords":"thermal barrier coatings, CMAS, Gd2O3-Yb2O3-Y2O3-stabilized ZrO2, surface states, wetting behavior, corrosion mechanism","lastPublishedDoi":"10.21203/rs.3.rs-6611295/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-6611295/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThermal barrier coatings (TBCs), critical for enhancing the efficiency of aircraft engines, are susceptible to corrosion by CaO-MgO-Al\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-SiO\u003csub\u003e2\u003c/sub\u003e (CMAS). In this study, Gd\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-Yb\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-Y\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e-stabilized ZrO\u003csub\u003e2\u003c/sub\u003e (GYYSZ) TBCs were prepared via atmospheric plasma spraying, and different surface states were obtained through mechanical grinding. The corrosion behavior of CMAS on coatings with different surface roughness was researched, and the corrosion mechanism was explained. The diffusion area of CMAS on the ground coatings surface is smaller, and the contact angle with the ground coatings is larger, compared with the coatings without mechanical polishing. Many spherical particles formed in the GYYSZ coatings after being corroded by CMAS at 1250\u0026deg;C, but demonstrating exceptional phase stability with retention of cubic phase throughout the 20 h exposure period. The ground coatings display fewer spherical particles than the as-sprayed coatings under the same corrosion conditions. The ground coatings manifest more residual CMAS on their surface, indicating that less CMAS penetrates into the coatings. This study suggests that the ground coatings significantly inhibit CMAS wetting and exhibit superior CMAS corrosion resistance compared to the as-sprayed coatings.\u003c/p\u003e","manuscriptTitle":"CMAS corrosion resistance of Gd2O3-Yb2O3-Y2O3-stabilized ZrO2 coatings with different surface states","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-05-15 13:25:27","doi":"10.21203/rs.3.rs-6611295/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"reviewerAgreed","content":"","date":"2025-07-11T03:27:43+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-05-13T09:03:37+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-05-12T04:27:32+00:00","index":"","fulltext":""},{"type":"submitted","content":"International Journal of Mechanical and Materials Engineering","date":"2025-05-07T06:58:25+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"international-journal-of-mechanical-and-materials-engineering","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"ijme","sideBox":"Learn more about [International Journal of Mechanical and Materials Engineering](http://ijmme.springeropen.com)","snPcode":"40712","submissionUrl":"https://www.editorialmanager.com/ijme/default2.aspx","title":"International Journal of Mechanical and Materials Engineering","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Open","inReviewEnabled":true,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"d59e29c7-1f93-45c2-8e62-a9d609da44af","owner":[],"postedDate":"May 15th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2025-05-15T13:25:27+00:00","versionOfRecord":[],"versionCreatedAt":"2025-05-15 13:25:27","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-6611295","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-6611295","identity":"rs-6611295","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}