Abstract:Dense monolithic (5RE0.2)2SixO2x+3/SiOC (RE=Yb, Ho, Er, Lu, Tb, Tm, Gd, x=1 or 2) ceramic nanocomposites were fabricated from rare-earth acetates and polysiloxane via the polymer-derived ceramics route coupled with spark plasma sintering. The resistance of the ceramic nanocomposites to CaO-MgO-Al2O3-SiO2 (CMAS) corrosion at 1 300-1 500 ℃, along with the underlying corrosion mechanisms, was investigated using X-ray diffractometer, scanning electron microscope, and transmission electron microscope. The results indicate that the ceramic nanocomposites comprise a SiOC matrix with a uniformly distributed high-entropy rare-earth silicate phase (5RE0.2)2SixO2x+3. The ceramic nanocomposites exhibit low mass loss and a thin corrosion layer at 1 300- 1 500 ℃, demonstrating excellent CMAS corrosion resistance. This superior performance is primarily attributed to the formation of a Ca3(5RE)2(Si3O9)2 cyclosilicate layer, resulting from the reaction between the (5RE0.2)2SixO2x+3phase and the molten CMAS, which effectively inhibit further infiltration. Furthermore, the specific rare-earth element in the (5RE0.2)2SixO2x+3 phase plays a crucial role in the CMAS corrosion resistance of the ceramic nanocomposites. Gd-containing ceramic nanocomposites exhibit optimal long-term resistance at 1 300 ℃, with a mass loss of only 3.6% after 20 h of corrosion. In contrast, Tb-containing ceramic nanocomposites demonstrate superior performance at a higher temperature, resulting in a remarkably thin corrosion layer of merely 20 μm after corrosion at 1 500 ℃ for 5 h.
[1] DAROLIA R.Thermal barrier coatings technology: critical review, progress update, remaining challenges and prospects[J]. International Materials Reviews, 2013, 58(6): 315-348. [2] 钟鑫, 牛亚然, 郑学斌, 等. 稀土硅酸盐环境障涂层耐水氧腐蚀研究进展[J]. 中国材料进展, 2025, 44(2): 134-145. ZHONG Xin, NIU Yaran, ZHENG Xuebin, et al.Research progress on water vapor corrosion of rare-earth silicates environmental barrier coatings[J]. Materials China, 2025, 44(2): 134-145. [3] 喻晓峰, 史平平, 赵丹阳, 等. 热/环境障涂层用稀土铪酸盐的抗腐蚀性能研究现状[J]. 粉末冶金材料科学与工程, 2025, 30(4): 261-271. YU Xiaofeng, SHI Pingping, ZHAO Danyang, et al.Research status on the corrosion resistance of rare earth hafnates used in thermal/environmental barrier coatings[J]. Materials Science and Engineering of Powder Metallurgy, 2025, 30(4): 261-271. [4] 薛召露, 郭洪波, 宫声凯, 等. 新型热障涂层陶瓷隔热层材料[J]. 航空材料学报, 2018, 38(2): 10-20. XUE Zhaolu, GUO Hongbo, GONG Shengkai, et al.Novel ceramic materials for thermal barrier coatings[J]. Journal of Aeronautical Materials, 2018, 38(2): 10-20. [5] 邱海鹏, 关星宇, 徐俊杰, 等. 基体改性对SiC/SiC复合材料高温抗氧化性能的影响[J]. 现代技术陶瓷, 2023, 44(3): 183-192. QIU Haipeng, GUAN Xingyu, XU Junjie, et al.Influence of matrix modification on the oxidation resistance of SiC/SiC composites[J]. Advanced Ceramics, 2023, 44(3): 183-192. [6] 王岭, 焦健, 焦春荣. 陶瓷基复合材料环境障涂层研究进展[J]. 航空制造技术, 2014(6): 50-53. WANG ling, JIAO Jian, JIAO Chunrong. Research progress of environmental barrier coatings for SiC ceramic matrix composites[J]. Aeronautical Manufacturing Technology, 2014(6): 50-53. [7] FISCHER T H, ALMLOF J.General methods for geometry and wave function optimization[J]. The Journal of Physical Chemistry, 1992, 96(24): 9768-9774. [8] XIAO G Z, SHEN Q Y, TIAN Y, et al.Investigation on the relation of microstructures and CMAS corrosion resistance of high entropy RE disilicates[J]. Corrosion Science, 2024, 227: 111727. [9] CORMAN G S, LUTHRA K L.Development history of GE’s prepreg melt infiltrated ceramic matrix composite material and applications[J]. Comprehensive Composite Materials II, 2018, 5: 325-338. [10] LEE K N.Key durability issues with mullite-based environmental barrier coatings for Si-based ceramics[J]. Journal of Engineering for Gas Turbines and Power, 2000, 122(4): 632-636. [11] TRESSLER R E, MEISER M D, YONUSHONIS T.Molten salt corrosion of SiC and Si3N4 ceramics[J]. Journal of the American Ceramic Society, 1976, 59(5/6): 278-279. [12] LUCATO S L D E, SUDRE O H, MARSHALL D B. A method for assessing reactions of water vapor with materials in high-speed, high-temperature flow[J]. Journal of the American Ceramic Society, 2011, 94: s186-s195. [13] RICHARDS B T, SEHR S, DE FRANQUEVILLE F, et al.Fracture mechanisms of ytterbium monosilicate environmental barrier coatings during cyclic thermal exposure[J]. Acta Materialia, 2016, 103: 448-460. [14] 赵春玲, 杨博, 李阔, 等. 陶瓷基复合材料表面环境障涂层材料研究进展[J]. 中国材料进展, 2021, 40(4): 257-266. ZHAO Chunling, YANG Bo, LI Kuo, et al.Research progress on environmental barrier coatings materials for ceramic matrix composites[J]. Materials China, 2021, 40(4): 257-266. [15] MESQUITA-GUIMARÃES J, GARCÍA E, MIRANZO P, et al. Mullite-YSZ multilayered environmental barrier coatings tested in cycling conditions under water vapor atmosphere[J]. Surface and Coatings Technology, 2012, 209: 103-109. [16] 贺世美, 牟仁德, 陆峰, 等. BSAS环境障涂层抗水蒸汽性及其失效机理[J]. 失效分析与预防, 2011, 6(1): 44-49. HE Shimei, MU Rende, LU Feng, et al.Vapor resistance and failure mechanism of BSAS environment barrier coatings[J]. Failure Analysis and Prevention, 2011, 6(1): 44-49. [17] 侯伟骜, 卢晓亮, 高丽华, 等. Yb2SiO5稀土硅酸盐环境障涂层研究进展[J]. 热喷涂技术, 2019, 11(3): 7-13. HOU Weiao, LU Xiaoliang, GAO Lihua, et al.Research progress on Yb2SiO5 rare earth silicates environmental barrier coatings[J]. Thermal Spray Technology, 2019, 11(3): 7-13. [18] STOKES J L, HARDER B J, WIESNER V L, et al.High-temperature thermochemical interactions of molten silicates with Yb2Si2O7 and Y2Si2O7 environmental barrier coating materials[J]. Journal of the European Ceramic Society, 2019, 39(15): 5059-5067. [19] CHEN P J, XIAO P, LI Z, et al.Water vapor corrosion behavior and failure mechanism of air sprayed bi-layer Yb2Si2O7/SiC and tri-layer Yb2Si2O7/(SiCw-mullite)/SiC environmental barrier coating[J]. Advanced Powder Materials, 2023, 2(1): 100064. [20] AL-HUNAISHI S, BLIN A, HARADA N, et al.Rare-earth doped yttrium silicate (Y2SiO5) thin films grown by chemical vapour deposition for quantum technologies[J]. Journal of Luminescence, 2024, 271: 120595. [21] 栾赛伟, 郭瑞, 张蕾, 等. Dy、Ho稀土协同作用对X9R型钛酸钡基陶瓷介电性能影响研究[J]. 现代技术陶瓷, 2024, 45(6): 530-540. LUAN Saiwei, GUO Rui, ZHANG Lei, et al.Study on the synergistic effect of Dy and Ho rare earths on the dielectric properties of X9R BaTiO3-based ceramic[J]. Advanced Ceramics, 2024, 45(6): 530-540. [22] LEE K N, FOX D S, BANSAL N P.Rare earth silicate environmental barrier coatings for SiC/SiC composites and Si3N4 ceramics[J]. Journal of the European Ceramic Society, 2005, 25(10): 1705-1715. [23] 田志林, 王京阳. 稀土硅酸盐陶瓷材料研究进展[J]. 现代技术陶瓷, 2018, 39(5): 295-320. TIAN Zhilin, WANG Jingyang.Research progress of rare earth silicate ceramics[J]. Advanced Ceramics, 2018, 39(5): 295-320. [24] 周邦阳, 崔永静, 王长亮, 等. 稀土硅酸盐环境障涂层研究进展[J]. 材料工程, 2023, 51(12): 12-23. ZHOU Bangyang, CUI Yongjing, WANG Changliang, et al.Research progress in rare earth silicate environmental barrier coatings[J]. Journal of Materials Engineering, 2023, 51(12): 12-23. [25] TURCER L R, KRAUSE A R, GARCES H F, et al.Environmental-barrier coating ceramics for resistance against attack by molten calcia-magnesia-aluminosilicate (CMAS) glass: part I, YAlO3 and γ-Y2Si2O7[J]. Journal of the European Ceramic Society, 2018, 38(11): 3905-3913. [26] 陈克丕, 李泽民, 马金旭, 等. 高熵陶瓷材料研究进展与展望[J]. 陶瓷学报, 2020, 41(2): 157-163. CHEN Kepi, LI Zemin, MA Jinxu, et al.Research progress and prospect of high-entropy ceramic materials[J]. Journal of Ceramics, 2020, 41(2): 157-163. [27] 顾俊峰, 邹冀, 张帆, 等. 高熵陶瓷材料研究进展[J]. 中国材料进展, 2019, 38(9): 855-865. GU Junfeng, ZOU Ji, ZHANG Fan, et al.Recent progress in high-entropy ceramic materials[J]. Materials China, 2019, 38(9): 855-865. [28] 魏福双, 刘勇, 张晓东, 等. 高熵陶瓷的制备及在热/环境障涂层中的应用现状[J]. 航空制造技术, 2021, 64(20): 92-101. WEI Fushuang, LIU Yong, ZHANG Xiaodong, et al.Preparation of high-entropy ceramics and their application status in thermal/environmental barrier coatings[J]. Aeronautical Manufacturing Technology, 2021, 64(20): 92-101. [29] ZHANG Y H, XIE M, WANG Z G, et al.Exploring the increasing behavior of thermal conductivity for high-entropy zirconates at high temperatures[J]. Scripta Materialia, 2023, 228: 115328. [30] RICHARDS B T, YOUNG K A, DE FRANCQUEVILLE F, et al.Response of ytterbium disilicate-silicon environmental barrier coatings to thermal cycling in water vapor[J]. Acta Materialia, 2016, 106: 1-14. [31] 王觅堂, 程金树. 稀土掺杂对硅酸盐玻璃粘度及热膨胀性能影响[J]. 武汉理工大学学报, 2010, 32(22): 72-75. WANG Mitang, CHENG Jinshu.Effect of rare earths on viscosity and thermal expansion of silicate glass[J]. Journal of Wuhan University of Technology, 2010, 32(22): 72-75. [32] WANG X, CHENG M H, XIAO G Z, et al.Preparation and corrosion resistance of high-entropy disilicate (Y0.25Yb0.25Er0.25Sc0.25)2Si2O7 ceramics[J]. Corrosion Science, 2021, 192: 109786. [33] CHEN H, XIANG H M, DAI F Z, et al.High entropy (Yb0.25Y0.25Lu0.25Er0.25)2SiO5 with strong anisotropy in thermal expansion[J]. Journal of Materials Science & Technology, 2020, 36: 134-139. [34] LIU J, ZHANG L T, LIU Q M, et al.Calcium-magnesium- aluminosilicate corrosion behaviors of rare-earth disilicates at 1 400 ℃[J]. Journal of the European Ceramic Society, 2013, 33(15/16): 3419-3428. [35] LU L, WEN T H, LI W, et al.Single-source-precursor synthesis of dense monolithic SiC/(Ti0.25Zr0.25Hf0.25Ta0.25)C ceramic nanocomposite with excellent high-temperature oxidation resistance[J]. Journal of the European Ceramic Society, 2024, 44(2): 595-609. [36] IONESCU E, LINCK C, FASEL C, et al.Polymer-derived SiOC/ZrO2 ceramic nanocomposites with excellent high-temperature stability[J]. Journal of the American Ceramic Society, 2010, 93(1): 241-250. [37] SUN L C, LUO Y X, TIAN Z L, et al.High temperature corrosion of (Er0.25Tm0.25Yb0.25Lu0.25)2Si2O7 environmental barrier coating material subjected to water vapor and molten calcium-magnesium-aluminosilicate (CMAS)[J]. Corrosion Science, 2020, 175: 108881. [38] 孙鲁超, 任孝旻, 杜铁锋, 等. 高熵化设计: 稀土硅酸盐材料关键性能优化新策略[J]. 无机材料学报, 2021, 36(4): 339-346. SUN Luchao, REN Xiaomin, DU Tiefeng, et al.High entropy engineering: new strategy for the critical property optimizations of rare earth silicates[J]. Journal of Inorganic Materials, 2021, 36(4): 339-346. [39] WEN Q B, YU Z J, RIEDEL R.The fate and role of in situ formed carbon in polymer-derived ceramics[J]. Progress in Materials Science, 2020, 109: 100623. [40] HUANG X, WEN Q B, ZHANG P P, et al.Polymer-derived high-entropy rare earth silicate nanocomposites with excellent water-vapor corrosion resistance at 1 200- 1 500 ℃[J]. Ceramics International, 2025, 51(22): 37255-37267. [41] RODRÍGUEZ-CARVAJAL J. Recent advances in magnetic structure determination by neutron powder diffraction[J]. Physica B: Condensed Matter, 1993, 192(1/2): 55-69. [42] HOLZWARTH U, GIBSON N.The scherrer equation versus the ‘Debye-Scherrer equation’[J]. Nature Nanotechnology, 2011, 6(9): 534. [43] 李影. Yb2Si2O7陶瓷制备及其高温CMAS熔盐与水蒸气/氧腐蚀行为[D]. 哈尔滨: 哈尔滨工业大学, 2021. LI Ying.Preparation and high temperature CMAS molten salt and water vapor/oxygen corrosion behavior of Yb2Si2O7 ceramics[D]. Harbin: Harbin Institute of Technology, 2021.