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<p>Yttria-stabilized zirconia (YSZ) has been widely adopt as a preferred thermal barrier coating(TBC) material for aircraft engine turbine blades due to the excellent performance, mature fabrication processes, and competitive cost. However, prolonged service under harsh high-temperature and high-pressure environments induces coating cracking or delamination, severely limiting engine service life and increasing costs. In this paper, a thermal barrier coating removal method was proposed based on the plasma electrolysis. With the objectives of minimizing substrate residual and preserving substrate integrity, systematic optimization of the electrolyte formulation was carried out using a single-factor variable approach. Experimental results indicate that the ammonium sulfate solution achieved a maximum removal rate of only 28.31% and left substantial residues. In contrast, an optimized composite electrolyte with 3.5% total salt concentration and an NH<sub>4</sub>F/KF mixing ratio of 1:3 attained a removal rate of 46.38%, representing a 64% improvement, while producing a surface condition suitable for subsequent recoating. Furthermore, the synergistic control of process parameters combined with the optimized formulation effectively reduced residual deposits, offering crucial technical support for the engineering application of plasma electrolytic removal in TBC repair.</p>

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Research on the Reaction Mechanism and Solution Formulation Optimization for Plasma Electrolytic Removal of Thermal Barrier Coatings

  • 期刊论文

  • 发表日期：

    2026年3月7日

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  • Chang Song,
  • Hong Liu,
  • Bo Song,
  • Zenan Sun,
  • Ben Wang

摘要

Yttria-stabilized zirconia (YSZ) has been widely adopt as a preferred thermal barrier coating(TBC) material for aircraft engine turbine blades due to the excellent performance, mature fabrication processes, and competitive cost. However, prolonged service under harsh high-temperature and high-pressure environments induces coating cracking or delamination, severely limiting engine service life and increasing costs. In this paper, a thermal barrier coating removal method was proposed based on the plasma electrolysis. With the objectives of minimizing substrate residual and preserving substrate integrity, systematic optimization of the electrolyte formulation was carried out using a single-factor variable approach. Experimental results indicate that the ammonium sulfate solution achieved a maximum removal rate of only 28.31% and left substantial residues. In contrast, an optimized composite electrolyte with 3.5% total salt concentration and an NH4F/KF mixing ratio of 1:3 attained a removal rate of 46.38%, representing a 64% improvement, while producing a surface condition suitable for subsequent recoating. Furthermore, the synergistic control of process parameters combined with the optimized formulation effectively reduced residual deposits, offering crucial technical support for the engineering application of plasma electrolytic removal in TBC repair.