Journal of Materials Science, Vol.46, No.17, 5709-5714, 2011
Calcia-doped yttria-stabilized zirconia for thermal barrier coatings: synthesis and characterization
Doping with other oxides has been a stabilization method of ZrO(2) for thermal barrier coating applications. Such a stabilized system is 7-8 mol% YO(1.5)-doped zirconia (7YSZ), which has been in use for around 20 years. In this study, calcia (CaO) and yttria (Y(2)O(3)) have been used for doping ZrO(2) to produce a stable single-phase cubic calcia-doped yttria-stabilized zirconia (CaYSZ). This has been synthesized using wet chemical synthesis as well as by solid-state synthesis. Unlike partially stabilized zirconia where 5 mol% CaO is doped into ZrO(2), CaYSZ has been found to be stable up to 1600 A degrees C. Detailed CaYSZ synthesis steps and phase characterization are presented. Wet chemical synthesis resulted in a stable single-phase CaYSZ just after 4 h treatment at 1400 A degrees C, whereas a 36 h annealing at 1600 A degrees C is required for CaYSZ synthesis during solid-state processing. The CaYSZ has been found stable even for 600 h at 1250 A degrees C. Coefficient of thermal expansion and sintering temperature of CaYSZ was found to be 11 x 10(-6) K(-1) and 1220 A degrees C, respectively, which are comparable to 7YSZ. An increase in sintering rate with increasing dopant concentration has also been observed.