Effects of calcium–magnesium–alumina–silicate and NaCl melting sequence on corrosion resistance of thermal barrier coatings

• The melting sequence of CMAS and NaCl significantly influences the failure mode of YSZ thermal barrier coatings, with mixed corrosion and NaCl-first melting leading to buckling failure, while CMAS-first melting results in spalling failure. • Experimental and finite element simulations reveal that the corrosion mechanisms are governed by the infiltration and reaction of molten salts, affecting the strain tolerance and phase stability of the coating. • The presence of NaCl accelerates the degradation of the bonding coating and promotes the formation of brittle spinel oxides, exacerbating TBC failure. • This study provides critical data for optimizing TBC systems to withstand complex corrosive environments, particularly in marine and high-temperature applications.