Interfacial structure and physical properties of high-entropy oxide coatings prepared via atmospheric plasma spraying

Abstract

The feasibility of using a high-entropy rare-earth oxide (REO) as a top coating material for thermal barrier coatings was explored using the atmospheric plasma spray technique. The microstructure and Vickers hardness of the coating layer were compared to those of an 8 mol % yttria-stabilized zirconia (8YSZ) top coating material. Macroscopic observations revealed the formation of a well-coated surface with no surface defects or delamination. Scanning electron microscopy images showed the presence of several parallel and vertical microcracks in the REO and 8YSZ coating layers. The origin of these cracks is attributed to differences in the coefficient of thermal expansion, very fast cooling, and process parameters. X-ray diffraction demonstrated the high phase stability and excellent thermal properties of REO due to the absence of phase transformation after plasma spray processing. The measured Vickers hardness of REO was 425 HV, which is lower than that of sintered REO powder and the 8YSZ coating.