Femtosecond laser-textured on Si bonded layer for enhancing water vapor corrosion resistance of environmental barrier coatings

Edge damage in high-temperature water vapor environment poses a major challenge for long-lasting environmental barrier coatings (EBCs). In this work, a bi-layer EBCs system was developed with a femtosecond laser-textured silicon layer and an Al-modified Yb₂Si₂O₇ (YbDS) surface layer to enhance the anti-spallation performance against water vapor corrosion. The reaction mechanisms of the Al-modified layer during water vapor exposure were investigated. Results showed that the porosity and TGO growth rate of the laser-textured and Al-modified (LT-Al) coating were significantly lower than those of Al-modified coating without laser texturing on Si layer. Simulations further confirmed that compressive stress regions within LT-Al coating effectively suppressed edge oxidation from propagating into the coating interior, thereby preserving coating integrity and ensuring long-term durability.