Erosion of atmospheric plasma sprayed rare earth oxide coatings under air suspended corundum particles

Atmospheric plasma sprayed (APS) zirconium oxide based coatings are used widely in aero engine components for providing thermal insulation, improving the corrosion and oxidation resistance. Despite its wide spread industrial use, little is known about the basic erosion behaviour and the mechanisms by which such coatings erode. In this paper, the erosive wear behaviours of Yttria Stabilized Zirconia (YSZ) coatings; Lanthanum Zirconate (LZ) coatings and Inconel 738 base material (BM) were studied and compared under air jet erosion conditions with corundum particles as erodent material. The erosion behaviour was studied with respect to the different porosity volume percentages of the coatings and the changes in velocity of erodent, impact angle of erodent and erodent particle flux. It was found that in solid particle erosion, the wear resistances of YSZ and LZ coatings were the best at their lowest porosity volume and it decreased with the increase in the percentage volume of porosity. There was a linear increase in the wear resistance with the increase in hardness. Further, relationships among the erosion parameters with respect to erosive wear loss were derived by using the response surface methodology and the erosion mechanisms were discussed adequately.