This invention discloses a method for vacuum-assisted drop-
coating to fill defects in
plasma-sprayed high-entropy thermal barrier coatings, relating to the field of high-temperature protective
coating technology. Based on a
synergistic mechanism of vacuum negative
pressure drive and in-situ generation of α-
alumina, this invention solves the problems of insufficient
penetration depth and poor compatibility in filling techniques. The vacuum environment can expel air from the
coating interior and defects, creating unobstructed penetration channels for aluminum
chloride sol. Combined with a multi-drop-coating process, the
sol can deeply penetrate internal defects such as pores and microcracks formed by
plasma spraying. After heat treatment at 1100℃, the
sol is in-situ transformed into an α-
alumina filling phase. This filling phase forms a single-phase
solid solution with the high-entropy rare-earth
zirconate coating with defective
fluorite structures, resulting in no harmful impurities and a tight interface. The small amount of
free space reserved after
alumina filling can release macroscopic thermal stress generated during thermal
cycling, preventing new cracks from forming due to
stress concentration and ensuring the stability of the coating.