This study provides an investigation into the influence of surface roughness, porosity, and chemistry on the wettability and infiltration behavior of calcia-magnesia-alumino-silicates (CMASs) in thermal and environmental barrier coatings (T/EBCs) used in high-temperature gas turbine engines. High-temperature contact angle measurements were performed at 1260 °C on 7 wt.% yttria-stabilized zirconia (7YSZ) and yttrium ytterbium disilicate (YYbDS, (Y_1/2Yb_1/2)₂Si₂O₇) to evaluate the interaction of CMASs with different surface finishes and coating microstructures. The findings demonstrate that porosity plays a dominant role in determining CMAS infiltration dynamics. In YYbDS, increasing porosity from 6.3% to 22.7% facilitated the formation of an apatite layer that limited CMAS penetration to approximately 2 µm. Surface roughness exhibited a subtler influence in that reducing Sa from 0.61 µm to 0.05 µm increased the change in the contact angle by ~2°, although its impact was found to be less significant compared to porosity and reactive chemistry. These results indicate that an integrated approach that optimizes porosity, chemistry, and surface morphology can significantly enhance CMAS resistance. The study emphasizes that leveraging both microstructural and chemical properties is critical to developing coatings capable of withstanding the harsh conditions encountered in aerospace environments.

Advanced thermal barrier coatings (TBCs) are essential for improving the efficiency and performance of gas turbine engines. Increasing engine operating temperatures and harsh service environments are pushing the current industry-standard 8 wt% yttria-stabilized zirconia (8YSZ) to its performance limits. High-rare-earth-oxide zirconates, such as Gd₂Zr₂O₇, have emerged as promising materials for next-generation engines due to their excellent high-temperature phase stability, lower thermal conductivity, and enhanced resistance to CMAS attack. In this work, dense vertically cracked (DVC) Gd₂Zr₂O₇/8YSZ bilayer coatings were developed using the air plasma spray (APS) process. Two approaches were employed for deposition of the NiCrAlYHfSi bond coat: (i) high-velocity oxygen fuel (HVOF), and (ii) APS flash-coated HVOF NiCrAlYHfSi bond coat. The durability of DVC TBC systems with the two bond coat types was evaluated by furnace cycling test (FCT) at 1125 °C. The TBC system with an APS flash-coated HVOF bond coat exhibited an FCT lifetime approximately twice that of the system with the HVOF bond coat alone. The improvement is primarily attributed to the higher surface roughness of the APS flash-coated bond coat, which enhances resistance to crack initiation, propagation, and linkage, thereby extending thermal cycling life.