Preparation of a tantalum-based MoSi2–Mo coating resistant to ultra-high-temperature thermal shock by a new two-step process.

[Display omitted] • A dense and uniform MoSi 2 -Mo coating on Ta substrate by a new MAIP-HAPC process. • MoSi 2 -Mo coating can protect Ta thermally shocked from room temperature to 1750 °C for 360 cycles without failure. • The excellent performance of the coating is due to the uniform structure and dense SiO 2. To develop an ultra-high-temperature resistant coating for a reusable thermal protection system, the preparation of a tantalum-based MoSi 2 -Mo coating by a new two-step process of multi-arc ion plating and halide activated pack cementation is presented. The coating has a dense structure and is well compatible with the tantalum substrate, which can be thermally shocked from room temperature to 1750 °C for 360 cycles without failure. The mechanism of the coating's excellent resistance to high-temperature thermal shocks is that a strong-binding gradient interface and a dense SiO 2 oxide scale with good oxygen resistance are formed by the high-temperature self-diffusion of Si. [ABSTRACT FROM AUTHOR]