Authors: F.I. Panteleenko, O. Devoino, V.V. Okovity, V.Yu. Blumenstein

Title of the article: Review of modern application of composite materials based on nickel alloys with ceramics systems for forming multilayer composite plasma coatings. Part 2

Year: 2026, Issue: 2, Pages: 56-66

Branch of knowledge: 2.6.1 Metal science and heat treatment of metals and alloys

Index UDK: 621.793.7:621.762

DOI: 10.26730/1999-4125-2026-2-56-66

Abstract: Low-quality fuel typically contains impurities such as Na and V, which can form corrosive salts of Na2SO4 and V2O5 on turbine blade coatings. These molten corrosive salts can penetrate the entire thickness of the YSZ coating through boundary spots and other defects in the YSZ coating, such as microcracks and open pores. The penetrated salts can then react with yttria (the stabilizing component of YSZ), depleting the stabilizer and causing a phase transformation from tetragonal zirconia to monoclinic zirconia, which can occur very quickly and efficiently during cooling. This phase transformation is also accompanied by a rapid volumetric expansion of 3-5%, leading to cracking and peeling of the YSZ coating. The addition of Al2O3 to the YSZ coating in atmospheric plasma-sprayed TBCs can significantly reduce the diffusion of molten salts into the YSZ layer and leads to higher hot corrosion resistance of the TBCs. It can be said that the layered TBC composite containing alumina can significantly prevent hot corrosion. Interestingly, Al2O3 cannot dissolve in ZrO2. Alumina (as a rigid matrix) is able to surround only ZrO2 particles in the TBC system. This phenomenon can create localized compressive stresses, which can hinder the phase transformation of tetragonal zirconia to the monoclinic phase. The tetragonal ZrO2 phase is not stable enough for long-term use under ambient conditions; however, the addition of alumina particles (Al2O3) to ZrO2 is one of the effective methods for inhibiting low-temperature degradation. In addition, the addition of micrometer-sized Al2O3 particles can lead to an additional increase in strength.

Key words: composite material nickel-chromium-aluminum-yttrium oxide ceramics plasma spraying durability and reliability of mechanisms heating rate of powder particles diffusion of molten salts hot corrosion

Receiving date: 30.12.2025

Approval date: 15.05.2026

Publication date: 29.06.2026

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