AI Chat Paper
Note: Please note that the following content is generated by AMiner AI. SciOpen does not take any responsibility related to this content.
{{lang === 'zh_CN' ? '文章概述' : 'Summary'}}
{{lang === 'en_US' ? '中' : 'Eng'}}
Chat more with AI
View PDF
Collect
Submit Manuscript AI Chat Paper
Show Outline
Outline
Show full outline
Hide outline
Outline
Show full outline
Hide outline
Review | Open Access

Progress in ceramic materials and structure design toward advanced thermal barrier coatings

Zhi-Yuan WEIa,Guo-Hui MENGa,Lin CHENa,Guang-Rong LIa,Mei-Jun LIUa,Wei-Xu ZHANGb,Li-Na ZHAOc,Qiang ZHANGd,Xiao-Dong ZHANGe,Chun-Lei WANf,Zhi-Xue QUg,Lin CHENh,Jing FENGh,Ling LIUi,Hui DONGj,Ze-Bin BAOk,Xiao-Feng ZHAOl,Xiao-Feng ZHANGm,Lei GUOn,Liang WANGo,Bo CHENGp,Wei-Wei ZHANGq,Peng-Yun XUr,Guan-Jun YANGa( )Hong-Neng CAIa( )Hong CUIc( )You WANGe( )Fu-Xing YEn( )Zhuang MAi( )Wei PANf( )Min LIUm( )Ke-Song ZHOUm( )Chang-Jiu LIa( )
State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi’an Jiaotong University, Xi’an 710049, China
State Key Laboratory for Strength and Vibration of Mechanical Structures, Department of Engineering Mechanics, School of Aerospace Engineering, Xi’an Jiaotong University, Xi’an 710049, China
Xi’an Aerospace Composite Research Institute, Xi’an 710025, China
AECC Beijing Institute of Aeronautical Materials, Beijing 100095, China
School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, China
State Key Laboratory of New Ceramics & Fine Processing, School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China
Faculty of Materials and Manufacturing, Key Laboratory of Advanced Functional Materials, Education Ministry of China, Faculty of Materials and Manufacturing, Beijing University of Technology, Beijing 100124, China
Faculty of Materials Science and Engineering, Kunming University of Science and Technology, Kunming 650093, China
School of Materials Science and Engineering, Beijing Institute of Technology, Beijing 100081, China
Xi’an Key Laboratory of High Performance Oil and Gas Field Materials, School of Materials Science and Engineering, Xi’an Shiyou University, Xi’an 710065, China
Shi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
Shanghai Key Laboratory of Advanced High-temperature Materials and Precision Forming, Shanghai Jiao Tong University, Shanghai 200240, China
National Engineering Laboratory for Modern Materials Surface Engineering Technology, the Key Lab of Guangdong for Modern Surface Engineering Technology, Institute of New Materials, Guangdong Academy of Sciences, Guangzhou 510650, China
School of Materials Science and Engineering, Tianjin University, Tianjin 300072, China
Integrated Computational Materials Research Centre, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 201899, China
State Key Laboratory of Advanced Processing and Recycling of Non-ferrous Metal, Lanzhou University of Technology, Lanzhou 730050, China
School of Materials Science and Engineering, Chang’an University, Xi’an 710064, China
Department of Mechanical and Electrical Engineering, Ocean University of China, Qingdao 266100, China

† These authors contributed equally to this work.

Show Author Information

Abstract

Thermal barrier coatings (TBCs) can effectively protect the alloy substrate of hot components in aeroengines or land-based gas turbines by the thermal insulation and corrosion/erosion resistance of the ceramic top coat. However, the continuous pursuit of a higher operating temperature leads to degradation, delamination, and premature failure of the top coat. Both new ceramic materials and new coating structures must be developed to meet the demand for future advanced TBC systems. In this paper, the latest progress of some new ceramic materials is first reviewed. Then, a comprehensive spalling mechanism of the ceramic top coat is summarized to understand the dependence of lifetime on various factors such as oxidation scale growth, ceramic sintering, erosion, and calcium-magnesium-aluminium-silicate (CMAS) molten salt corrosion. Finally, new structural design methods for high-performance TBCs are discussed from the perspectives of lamellar, columnar, and nanostructure inclusions. The latest developments of ceramic top coat will be presented in terms of material selection, structural design, and failure mechanism, and the comprehensive guidance will be provided for the development of next-generation advanced TBCs with higher temperature resistance, better thermal insulation, and longer lifetime.

References

[1]
Thakare JG, Pandey C, Mahapatra MM, et al. Thermal barrier coatings—A state of the art review. Met Mater Int 2021, 27: 1947-1968.
[2]
Chen HF, Zhang C, Liu YC, et al. Recent progress in thermal/environmental barrier coatings and their corrosion resistance. Rare Met 2020, 39: 498-512.
[3]
Lakiza SM, Grechanyuk MI, Ruban OK, et al. Thermal barrier coatings: Current status, search, and analysis. Powder Metall Met Ceram 2018, 57: 82-113.
[4]
Li CJ, Li Y, Yang GJ, et al. A novel plasma-sprayed durable thermal barrier coating with a well-bonded YSZ interlayer between porous YSZ and bond coat. J Therm Spray Technol 2012, 21: 383-390.
[5]
Sun JY, Pei YL, Li SS, et al. Improved mechanical properties of Ni-rich Ni3Al coatings produced by EB-PVD for repairing single crystal blades. Rare Met 2017, 36: 556-561.
[6]
Chevallier J, Isern L, Almandoz Forcen K, et al. Modelling evaporation in electron-beam physical vapour deposition of thermal barrier coatings. Emergent Mater 2021, 4: 1499-1513.
[7]
Li GR, Lv BW, Yang GJ, et al. Relationship between lamellar structure and elastic modulus of thermally sprayed thermal barrier coatings with intra-splat cracks. J Therm Spray Technol 2015, 24: 1355-1367.
[8]
Liu MJ, Zhang G, Lu YH, et al. Plasma spray-physical vapor deposition toward advanced thermal barrier coatings: A review. Rare Met 2020, 39: 479-497.
[9]
Von Niessen K, Gindrat M, Refke A. Vapor phase deposition using plasma spray-PVDTM. J Therm Spray Technol 2010, 19: 502-509.
[10]
Yu ZY, Wei LL, Guo XY, et al. Microstructural evolution, mechanical properties and degradation mechanism of PS-PVD quasi-columnar thermal barrier coatings exposed to glassy CMAS deposits. Rare Met 2018, .
[11]
Singh J, Wolfe DE. Review nano and macro-structured component fabrication by electron beam-physical vapor deposition (EB-PVD). J Mater Eng Perform 2005, 40: 1-26.
[12]
Bakan E, Vaßen R. Ceramic top coats of plasma-sprayed thermal barrier coatings: Materials, processes, and properties. J Therm Spray Technol 2017, 26: 992-1010.
[13]
Zhang WW, Li GR, Zhang Q, et al. Self-enhancing thermal insulation performance of bimodal-structured thermal barrier coating. J Therm Spray Technol 2018, 27: 1064-1075.
[14]
Zhao ZF, Chen H, Xiang HM, et al. High entropy defective fluorite structured rare-earth niobates and tantalates for thermal barrier applications. J Adv Ceram 2020, 9: 303-311.
[15]
Li F, Zhou L, Liu JX, et al. High-entropy pyrochlores with low thermal conductivity for thermal barrier coating materials. J Adv Ceram 2019, 8: 576-582.
[16]
Qu ZX, Wan CL, Pan W, et al. Thermal expansion and defect chemistry of MgO-doped Sm2Zr2O7. Chem Mater 2007, 19: 4913.
[17]
Guo L, Li BW, Cheng YX, et al. Composition optimization, high-temperature stability, and thermal cycling performance of Sc-doped Gd2Zr2O7 thermal barrier coatings: theoretical and experimental studies. J Adv Ceram 2022, 11: 454-469.
[18]
Xue Y, Zhao XQ, An YL, et al. High-entropy (La0.2Nd0.2Sm0.2Eu0.2Gd0.2)2Ce2O7: a potential thermal barrier material with improved thermo-physical properties. J Adv Ceram 2022, 11: 615-628.
[19]
Sun YN, Xiang HM, Dai FZ, et al. Preparation and properties of CMAS resistant bixbyite structured high-entropy oxides RE2O3 (RE = Sm, Eu, Er, Lu, Y, and Yb): Promising environmental barrier coating materials for Al2O3f/Al2O3 composites. J Adv Ceram 2021, 10: 596-613.
[20]
Li CJ, Li Y, Yang GJ, et al. Evolution of lamellar interface cracks during isothermal cyclic test of plasma-sprayed 8YSZ coating with a columnar-structured YSZ interlayer. J Therm Spray Technol 2013, 22: 1374-1382.
[21]
Dong H, Yang GJ, Cai HN, et al. Propagation feature of cracks in plasma-sprayed YSZ coatings under gradient thermal cycling. Ceram Int 2015, 41: 3481-3489.
[22]
Patel NV, Jordan EH, Sridharan S, et al. Cyclic furnace testing and life predictions of thermal barrier coating spallation subject to a step change in temperature or in cycle duration. Surf Coat Technol 2015, 275: 384-391.
[23]
Kishore MB, Lee HG, Abera AG, et al. Quantitative evaluation of partial delamination in thermal barrier coatings using ultrasonic C-scan imaging. Int J Precis Eng Manuf 2020, 21: 157-165.
[24]
Dai MQ, Song XM, Lin CC, et al. Investigation of microstructure changes in Al2O3-YSZ coatings and YSZ coatings and their effect on thermal cycle life. J Adv Ceram 2022, 11: 345-353.
[25]
Lee MJ, Lee BC, Lim JG, et al. Residual stress analysis of the thermal barrier coating system by considering the plasma spraying process. J Mech Sci Technol 2014, 28: 2161-2168.
[26]
Zhu JG, Chen W, Xie HM. Simulation of residual stresses and their effects on thermal barrier coating systems using finite element method. Sci China Phys Mech Astron 2015, 58: 1-10.
[27]
Fry AT, Patel M, Gorman D, et al. The effect of cracking of thermally grown oxide layers in thermal barrier coatings examined using FIB tomography and inverse modelling. Oxid Met 2021, 96: 157-168.
[28]
Huang H, Liu C, Ni LY, et al. Evaluation of TGO growth in thermal barrier coatings using impedance spectroscopy. Rare Met 2011, 30: 643-646.
[29]
Tsipas SA, Golosnoy IO, Damani R, et al. The effect of a high thermal gradient on sintering and stiffening in the top coat of a thermal barrier coating system. J Therm Spray Technol 2004, 13: 370-376.
[30]
Ahrens M, Lampenscherf S, Vaßen R, et al. Sintering and creep processes in plasma-sprayed thermal barrier coatings. J Therm Spray Technol 2004, 13: 432-442.
[31]
Zhang PP, Zhang XF, Li FH, et al. Hot corrosion behavior of YSZ thermal barrier coatings modified by laser remelting and Al deposition. J Therm Spray Technol 2019, 28: 1225-1238.
[32]
Arai M. Mechanistic study on the degradation of thermal barrier coatings induced by volcanic ash deposition. J Therm Spray Technol 2017, 26: 1207-1221.
[33]
Gomez Chavez JJ, Naraparaju R, Mechnich P, et al. Effects of yttria content on the CMAS infiltration resistance of yttria stabilized thermal barrier coatings system. J Mater Sci Technol 2020, 43: 74-83.
[34]
Guo L, Li G, Gan ZL. Effects of surface roughness on CMAS corrosion behavior for thermal barrier coating applications. J Adv Ceram 2021, 10: 472-481.
[35]
Li DX, Jiang P, Gao RH, et al. Experimental and numerical investigation on the thermal and mechanical behaviours of thermal barrier coatings exposed to CMAS corrosion. J Adv Ceram 2021, 10: 551-564.
[36]
Essa SK, Chen KY, Liu R, et al. Failure mechanisms of APS-YSZ-CoNiCrAlY thermal barrier coating under isothermal oxidation and solid particle erosion. J Therm Spray Technol 2021, 30: 424-441.
[37]
Doleker KM, Ahlatci H, Karaoglanli AC. Investigation of isothermal oxidation behavior of thermal barrier coatings (TBCs) consisting of YSZ and multilayered YSZ/Gd2Zr2O7 ceramic layers. Oxid Met 2017, 88: 109-119.
[38]
Ahmadian H, Kiahoseyni SR. Investigation of thermal shock resistant in three kinds thermal barrier cerium oxide coating (CeO2) with MCrAlY intermediate layer. SN Appl Sci 2019, 1: 1619.
[39]
Chen DY, Rocchio-Heller R, Dambra C. Segmented thermal barrier coatings for ID and OD components using the SinplexPro plasma torch. J Therm Spray Technol 2019, 28: 1664-1673.
[40]
Zhu W, Li ZY, Yang L, et al. Real-time detection of CMAS corrosion failure in APS thermal barrier coatings under thermal shock. Exp Mech 2020, 60: 775-785.
[41]
Li CJ, Dong H, Ding H, et al. The correlation of the TBC lifetimes in burner cycling test with thermal gradient and furnace isothermal cycling test by TGO effects. J Therm Spray Technol 2017, 26: 378-387.
[42]
Malvi B, Roy M. Elevated temperature erosion of plasma sprayed thermal barrier coating. J Therm Spray Technol 2021, 30: 1028-1037.
[43]
Clarke DR, Levi CG. Materials design for the next generation thermal barrier coatings. Annu Rev Mater Res 2003, 33: 383-417.
[44]
Clarke DR, Phillpot SR. Thermal barrier coating materials. Mater Today 2005, 8: 22-29.
[45]
Fergus JW. Zirconia and pyrochlore oxides for thermal barrier coatings in gas turbine engines. Metall Mater Trans E 2014, 1: 118-131.
[46]
Perepezko JH. The hotter the engine, the better. Science 2009, 326: 1068-1069.
[47]
Padture NP, Gell M, Jordan EH. Thermal barrier coatings for gas-turbine engine applications. Science 2002, 296: 280-284.
[48]
Li F, Li YY, Song ZX, et al. Grain growth characteristics of hydrothermally prepared yttria stabilized zirconia nanocrystals during calcination. Rare Metal Mat Eng 2017, 46: 0899-0905.
[49]
Kumar A, Gu S, Tabbara H, et al. Study of impingement of hollow ZrO2 droplets onto a substrate. Surf Coat Technol 2013, 220: 164-169.
[50]
Zhao LN, Zhang Z, Duan YG, et al. Preparation of yttria-stabilized zirconia hollow sphere with reduced shell thickness by controlling ambient temperature during plasma process. Coatings 2018, 8: 245.
[51]
Zhang Z, Zhao LN, Ma YP. Preparing hollow spherical hydroxyapatite powder with a thin shell structure by the plasma process with a heat preservation zone. Ceram Int 2019, 45: 19562-19566.
[52]
Solonenko OP, Gulyaev IP, Smirnov AV. Plasma processing and deposition of powdered metal oxides consisting of hollow spherical particles. Tech Phys Lett 2008, 34: 1050-1052.
[53]
Gulyaev IP. Production and modification of hollow powders in plasma under controlled pressure. J Phys Conf Ser 2013, 441: 012033.
[54]
Kulkarni A, Wang Z, Nakamura T, et al. Comprehensive microstructural characterization and predictive property modeling of plasma-sprayed zirconia coatings. Acta Mater 2003, 51: 2457-2475.
[55]
Chi W, Sampath S, Wang H. Ambient and high-temperature thermal conductivity of thermal sprayed coatings. J Therm Spray Technol 2006, 15: 773-778.
[56]
Tan Y, Srinivasan V, Nakamura T, et al. Optimizing compliance and thermal conductivity of plasma sprayed thermal barrier coatings via controlled powders and processing strategies. J Therm Spray Technol 2012, 21: 950-962.
[57]
Vaßen R, Czech N, Malléner W, et al. Influence of impurity content and porosity of plasma-sprayed yttria-stabilized zirconia layers on the sintering behaviour. Surf Coat Technol 2001, 141: 135-140.
[58]
Paul S, Cipitria A, Golosnoy IO, et al. Effects of impurity content on the sintering characteristics of plasma-sprayed zirconia. J Therm Spray Technol 2007, 16: 798-803.
[59]
Xie L, Dorfman MR, Cipitria A, et al. Properties and performance of high-purity thermal barrier coatings. J Therm Spray Technol 2007, 16: 804-808.
[60]
Vassen R, Cao XQ, Tietz F, et al. Zirconates as new materials for thermal barrier coatings. J Am Ceram Soc 2000, 83: 2023-2028.
[61]
Zhu DM, Nesbitt JA, Barrett CA, et al. Furnace cyclic oxidation behavior of multicomponent low conductivity thermal barrier coatings. J Therm Spray Technol 2004, 13: 84-92.
[62]
Ji XJ, Gong SK, Xu HB, et al. Influence of rare earth elements additions in YSZ ceramic coatings of thermal barrier coatings on lattice distortion. Acta Aeronautica Et Astronautica Sinica 2007, 28: 196-200. (in Chinese)
[63]
Bansal NP, Zhu DM. Effects of doping on thermal conductivity of pyrochlore oxides for advanced thermal barrier coatings. Mater Sci Eng A 2007, 459: 192-195.
[64]
Wu J, Padture NP, Klemens PG, et al. Thermal conductivity of ceramics in the ZrO2-GdO1.5 system. J Mater Res 2002, 17: 3193-3200.
[65]
Wakeshima M, Nishimine H, Hinatsu Y. Crystal structures and magnetic properties of rare earth tantalates RE3TaO7 (RE = rare earths). J Phys Condens Matter 2004, 16: 4103-4120.
[66]
Chesnaud A, Braida M-D, Estradé S, et al. High-temperature anion and proton conduction in RE3NbO7 (RE = La, Gd, Y, Yb, Lu) compounds. J Eur Ceram Soc 2015, 35: 3051-3061.
[67]
Cai L, Nino JC. Structure and dielectric properties of Ln3NbO7 (Ln = Nd, Gd, Dy, Er, Yb and Y). J Eur Ceram Soc 2007, 27: 3971-3976.
[68]
Abe R, Higashi M, Sayama K, et al. Photocatalytic activity of R3MO7 and R2Ti2O7 (R = Y, Gd, La; M = Nb, Ta) for water splitting into H2 and O2. J Phys Chem B 2006, 110: 2219-2226.
[69]
Xiang HM, Xing Y, Dai FZ, et al. High-entropy ceramics: Present status, challenges, and a look forward. J Adv Ceram 2021, 10: 385-441.
[70]
Huang MZ, Li LY, Feng YJ, et al. Y3NbO7 transparent ceramic series for high refractive index optical lenses. J Am Ceram Soc 2021, 104: 5776-5783.
[71]
Masuno A, Inoue H, Yoshimoto K, et al. Thermal and optical properties of La2O3-Nb2O5 high refractive index glasses. Opt Mater Express 2014, 4: 710-718.
[72]
Yang J, Qian X, Pan W, et al. Diffused lattice vibration and ultralow thermal conductivity in the binary Ln-Nb-O oxide system. Adv Mater 2019, 31: 1808222.
[73]
Chen L, Wu P, Song P, et al. Potential thermal barrier coating materials: RE3NbO7 (RE = La, Nd, Sm, Eu, Gd, Dy) ceramics. J Am Ceram Soc 2018, 101: 4503-4508.
[74]
Huang MZ, Liu XY, Zhang P, et al. Thermal conductivity modeling on highly disordered crystalline Y1-xNbxO1.5+x: Beyond the phonon scenario. Appl Phys Lett 2021, 118: 073901.
[75]
Yang J, Pan W, Han Y, et al. Mechanical properties, oxygen barrier property, and chemical stability of RE3NbO7 for thermal barrier coating. J Am Ceram Soc 2020, 103: 2302-2308.
[76]
Chen L, Guo J, Zhu YK, et al. Features of crystal structures and thermo-mechanical properties of weberites RE3NbO7 (RE = La, Nd, Sm, Eu, Gd) ceramics. J Am Ceram Soc 2021, 104: 404-412.
[77]
Zhang P, Feng YJ, Li Y, et al. Thermal and mechanical properties of ferroelastic RENbO4 (RE = Nd, Sm, Gd, Dy, Er, Yb) for thermal barrier coatings. Scripta Mater 2020, 180: 51-56.
[78]
Wu FS, Wu P, Zhou YX, et al. The thermo-mechanical properties and ferroelastic phase transition of RENbO4 (RE = Y, La, Nd, Sm, Gd, Dy, Yb) ceramics. J Am Ceram Soc 2020, 103: 2727-2740.
[79]
Zhu JT, Xu J, Zhang P, et al. Enhanced mechanical and thermal properties of ferroelastic high-entropy rare-earth-niobates. Scripta Mater 2021, 200: 113912.
[80]
Sarin P, Hughes RW, Lowry DR, et al. High-temperature properties and ferroelastic phase transitions in rare-earth niobates (LnNbO4). J Am Ceram Soc 2014, 97: 3307-3319.
[81]
Wang J, Zhou Y, Chong XY, et al. Microstructure and thermal properties of a promising thermal barrier coating: YTaO4. Ceram Int 2016, 42: 13876-13881.
[82]
Zhang QL, Zhou WL, Liu WP, et al. Crystal growth by Czochralski method and spectral properties of Yb3+:GdTaO4. Acta Optica Sinica 2010, 30: 849-853. (in Chinese)
[83]
Feng J, Shian S, Xiao B, et al. First-principles calculations of the high-temperature phase transformation in yttrium tantalate. Phys Rev B 2014, 90: 094102.
[84]
Wang J, Chong XY, Zhou R, et al. Microstructure and thermal properties of RETaO4 (RE = Nd, Eu, Gd, Dy, Er, Yb, Lu) as promising thermal barrier coating materials. Scripta Mater 2017, 126: 24-28.
[85]
Ubaldini A, Carnasciali MM. Raman characterisation of powder of cubic RE2O3 (RE = Nd, Gd, Dy, Tm, and Lu), Sc2O3 and Y2O3. J Alloys Compd 2008, 454: 374-378.
[86]
Swalin RA, Rice SA. Thermodynamics of solids. Phys Today 1963, 16: 72-74.
[87]
Zhang YL, Guo L, Yang YP, et al. Influence of Gd2O3 and Yb2O3 co-doping on phase stability, thermo-physical properties and sintering of 8YSZ. Chin J Aeronaut 2012, 25: 948-953.
[88]
Chen L, Hu MY, Wu P, et al. Thermal expansion performance and intrinsic lattice thermal conductivity of ferroelastic RETaO4 ceramics. J Am Ceram Soc 2019, 102: 4809-4821.
[89]
Du AB, Wan CL, Qu ZX, et al. Thermal conductivity of monazite-type REPO4 (RE = La, Ce, Nd, Sm, Eu, Gd). J Am Ceram Soc 2009, 92: 2687-2692.
[90]
Chen L, Feng J. Influence of HfO2 alloying effect on microstructure and thermal conductivity of HoTaO4 ceramics. J Adv Ceram 2019, 8: 537-544.
[91]
Wu P, Hu MY, Chen L, et al. Investigation on microstructures and thermo-physical properties of ferroelastic (Y1-xDyx)TaO4 ceramics. Materialia 2018, 4: 478-486.
[92]
Wu J, Wei XZ, Padture NP, et al. Low-thermal-conductivity rare-earth zirconates for potential thermal-barrier-coating applications. J Am Ceram Soc 2002, 85: 3031-3035.
[93]
Maloney MJ. Thermal barrier coating systems and materials. U.S. patent 6 924 040, Aug. 2005.
[94]
Feng J, Xiao B, Zhou R, et al. Thermal conductivity of rare earth zirconate pyrochlore from first principles. Scripta Mater 2013, 68: 727-730.
[95]
Wang JD, Pan W, Xu Q, et al. Thermal conductivity of the new candidate materials for thermal barrier coatings. Key Eng Mater 2005, 280-283: 1503-1506.
[96]
Xu Q, Pan W, Wang JD, et al. Preparation and thermophysical properties of Dy2Zr2O7 ceramic for thermal barrier coatings. Mater Lett 2005, 59: 2804-2807.
[97]
Aruna ST, Sanjeeviraja C, Balaji N, et al. Properties of plasma sprayed La2Zr2O7 coating fabricated from powder synthesized by a single-step solution combustion method. Surf Coat Technol 2013, 219: 131-138.
[98]
Yu JH, Zhao HY, Tao SY, et al. Thermal conductivity of plasma sprayed Sm2Zr2O7 coatings. J Eur Ceram Soc 2010, 30: 799-804.
[99]
Wan CL, Qu ZX, Du AB, et al. Order-disorder transition and unconventional thermal conductivities of the (Sm1-xYbx)2Zr2O7 series. J Am Ceram Soc 2011, 94: 592-596.
[100]
Li T, Ma Z, Liu L, et al. Thermal properties of Sm2Zr2O7-NiCr2O4 composites. Ceram Int 2014, 40: 11423-11426.
[101]
Ma Z, Zhang Q, Liu L, et al. Preparation and heat insulating capacity of Sm2Zr2O7-SiC composites based on photon thermal transport. J Adv Ceram 2020, 9: 454-461.
[102]
Fan QB, Zhang F, Wang FC, et al. Molecular dynamics calculation of thermal expansion coefficient of a series of rare-earth zirconates. Comput Mater Sci 2009, 46: 716-719.
[103]
Shimamura K, Arima T, Idemitsu K, et al. Thermophysical properties of rare-earth-stabilized zirconia and zirconate pyrochlores as surrogates for actinide-doped zirconia. Int J Thermophys 2007, 28: 1074-1084.
[104]
Zhou HM, Yi DQ. Effect of rare earth doping on thermo-physical properties of lanthanum zirconate ceramic for thermal barrier coatings. J Rare Earths 2008, 26: 770-774.
[105]
Liu L, Wang FC, Ma Z, et al. Thermophysical properties of (MgxLa0.5-xSm0.5)2(Zr0.7Ce0.3)2O7-x (x = 0, 0.1, 0.2, 0.3) ceramic for thermal barrier coatings. J Am Ceram Soc 2011, 94: 675-678.
[106]
Liu L, Xu Q, Wang FC, et al. Thermophysical properties of complex rare-earth zirconate ceramic for thermal barrier coatings. J Am Ceram Soc 2008, 91: 2398-2401.
[107]
Xue ZL, Wu SQ, Qian LH, et al. Influence of Y2O3 and Ta2O5 co-doping on microstructure and thermal conductivity of Gd2Zr2O7 ceramics. J Mater Eng Perform 2020, 29: 1206-1213.
[108]
Tian WZ, Liu L, Ma Z, et al. The preparation and properties of Sm2Zr2O7 coatings by plasma spraying. Mater Res Innov 2015, 19: S24-S28.
[109]
Guo W, Ma Z, Liu L, et al. Influence of feedstock on the microstructure of Sm2Zr2O7 thermal barrier coatings deposited by plasma spraying. J Therm Spray Technol 2018, 27: 1524-1531.
[110]
Doleker KM, Ozgurluk Y, Karaoglanli AC. TGO growth and kinetic study of single and double layered TBC systems. Surf Coat Technol 2021, 415: 127135.
[111]
Jasik A, Moskal G, Mikuśkiewicz M, et al. Oxidation behavior of the monolayered La2Zr2O7, composite La2Zr2O7 + 8YSZ, and double-cceramic layered La2Zr2O7/ La2Zr2O7 + 8YSZ/8YSZ thermal barrier coatings. Materials 2020, 13: 3242.
[112]
Kuroda S, Clyne TW. The quenching stress in thermally sprayed coatings. Thin Solid Films 1991, 200: 49-66.
[113]
Li CJ, Ohmori A. Relationships between the microstructure and properties of thermally sprayed deposits. J Therm Spray Technol 2002, 11: 365-374.
[114]
Bohn S, Douady S, Couder Y. Four sided domains in hierarchical space dividing patterns. Phys Rev Lett 2005, 94: 054503.
[115]
Bohn S. Hierarchical crack patterns: A comparison with two-dimensional soap foams. Colloids Surf A Physicochem Eng Aspects 2005, 263: 46-51.
[116]
Chen L, Yang GJ, Li CX, et al. Hierarchical formation of intrasplat cracks in thermal spray ceramic coatings. J Therm Spray Technol 2016, 25: 959-970.
[117]
Chen L, Yang GJ, Li CX, et al. Edge effect on crack patterns in thermally sprayed ceramic splats. J Therm Spray Technol 2017, 26: 302-314.
[118]
Li CJ, Li JL. Transient contact pressure during flattening of thermal spray droplet and its effect on splat formation. J Therm Spray Technol 2004, 13: 229-238.
[119]
Jiang XY, Wan YP, Herman H, et al. Role of condensates and adsorbates on substrate surface on fragmentation of impinging molten droplets during thermal spray. Thin Solid Films 2001, 385: 132-141.
[120]
Xue MX, Chandra S, Mostaghimi J. Investigation of splat curling up in thermal spray coatings. J Therm Spray Technol 2006, 15: 531-536.
[121]
Chen L, Yang GJ. Epitaxial growth and cracking of highly tough 7YSZ splats by thermal spray technology. J Adv Ceram 2018, 7: 17-29.
[122]
Chen L, Yang GJ. Hetero-orientation epitaxial growth of TiO2 splats on polycrystalline TiO2 substrate. J Therm Spray Technol 2018, 27: 880-897.
[123]
Chen L, Gao LL, Yang GJ. Imaging slit pores under delaminated splats by white light interference. J Therm Spray Technol 2018, 27: 319-335.
[124]
Chen L, Yang GJ. Epitaxial growth and cracking mechanisms of thermally sprayed ceramic splats. J Therm Spray Technol 2018, 27: 255-268.
[125]
Chen L, Yang GJ, Li CX. Formation of lamellar pores for splats via interfacial or sub-interfacial delamination at chemically bonded region. J Therm Spray Technol 2017, 26: 315-326.
[126]
Chen L, Yang GJ. Anomalous epitaxial growth in thermally sprayed YSZ and LZ splats. J Therm Spray Technol 2017, 26: 1168-1182.
[127]
Ranjbar-Far M, Absi J, Mariaux G, et al. Effect of residual stresses and prediction of possible failure mechanisms on thermal barrier coating system by finite element method. J Therm Spray Technol 2010, 19: 1054-1061.
[128]
Tahir A, Li GR, Liu MJ, et al. Improving WC-Co coating adhesive strength on rough substrate: Finite element modeling and experiment. J Mater Sci Technol 2020, 37: 1-8.
[129]
Bobzin K, Bagcivan N, Parkot D, et al. Modeling and simulation of microstructure formation for porosity prediction in thermal barrier coatings under air plasma spraying condition. J Therm Spray Technol 2009, 18: 975-980.
[130]
Samadi H, Coyle TW. Modeling the build-up of internal stresses in multilayer thick thermal barrier coatings. J Therm Spray Technol 2009, 18: 996-1003.
[131]
Wu LF, Zhu JG, Xie HM. Numerical and experimental investigation of residual stress in thermal barrier coatings during APS process. J Therm Spray Technol 2014, 23: 653-665.
[132]
Li SL, Qi HY, Song JN, et al. Effect of bond-coat surface roughness on failure mechanism and lifetime of air plasma spraying thermal barrier coatings. Sci China Technol Sci 2019, 62: 989-995.
[133]
Wei ZY, Cai HN, Feng RX, et al. The combined effect of creep and TGO growth on the cracking driving force in a plasma-sprayed thermal barrier system. J Therm Spray Technol 2019, 28: 1000-1016.
[134]
Bäker M, Seiler P. A guide to finite element simulations of thermal barrier coatings. J Therm Spray Technol 2017, 26: 1146-1160.
[135]
Krishnasamy J, Ponnusami SA, Turteltaub S, et al. Numerical investigation into the effect of splats and pores on the thermal fracture of air plasma-sprayed thermal barrier coatings. J Therm Spray Technol 2019, 28: 1881-1892.
[136]
Ranjbar-Far M, Absi J, Mariaux G. Finite element modeling of the different failure mechanisms of a plasma sprayed thermal barrier coatings system. J Therm Spray Technol 2012, 21: 1234-1244.
[137]
Vaßen R, Bakan E, Mack D, et al. Performance of YSZ and Gd2Zr2O7/YSZ double layer thermal barrier coatings in burner rig tests. J Eur Ceram Soc 2020, 40: 480-490.
[138]
Li GR, Yang GJ. Understanding of degradation-resistant behavior of nanostructured thermal barrier coatings with bimodal structure. J Mater Sci Technol 2019, 35: 231-238.
[139]
Paul S, Cipitria A, Tsipas SA, et al. Sintering characteristics of plasma sprayed zirconia coatings containing different stabilisers. Surf Coat Technol 2009, 203: 1069-1074.
[140]
Cernuschi F, Bison PG, Marinetti S, et al. Thermophysical, mechanical and microstructural characterization of aged free-standing plasma-sprayed zirconia coatings. Acta Mater 2008, 56: 4477-4488.
[141]
Shinozaki M, Clyne TW. A methodology, based on sintering-induced stiffening, for prediction of the spallation lifetime of plasma-sprayed coatings. Acta Mater 2013, 61: 579-588.
[142]
Cocks A, Fleck N, Lampenscherf S. A brick model for asperity sintering and creep of APS TBCs. J Mech Phys Solids 2014, 63: 412-431.
[143]
Li GR, Cheng B, Yang GJ, et al. Strain-induced stiffness-dependent structural changes and the associated failure mechanism in TBCs. J Eur Ceram Soc 2017, 37: 3609-3621.
[144]
Cipitria A, Golosnoy IO, Clyne TW. A sintering model for plasma-sprayed zirconia thermal barrier coatings. Part II: Coatings bonded to a rigid substrate. Acta Mater 2009, 57: 993-1003.
[145]
Lv BW, Fan XL, Xie H, et al. Effect of neck formation on the sintering of air-plasma-sprayed thermal barrier coating system. J Eur Ceram Soc 2017, 37: 811-821.
[146]
Cheng B, Yang N, Zhang Q, et al. Sintering induced the failure behavior of dense vertically crack and lamellar structured TBCs with equivalent thermal insulation performance. Ceram Int 2017, 43: 15459-15465.
[147]
Yang L, Liu QX, Zhou YC, et al. Finite element simulation on thermal fatigue of a turbine blade with thermal barrier coatings. J Mater Sci Technol 2014, 30: 371-380.
[148]
Xie H, Xie YC, Yang GJ, et al. Modeling thermal conductivity of thermally sprayed coatings with intrasplat cracks. J Therm Spray Technol 2013, 22: 1328-1336.
[149]
Fauchais P, Fukumoto M, Vardelle A, et al. Knowledge concerning splat formation: An invited review. J Therm Spray Technol 2004, 13: 337-360.
[150]
Zhong X, Zhu T, Niu YR, et al. Effect of microstructure evolution and crystal structure on thermal properties for plasma-sprayed RE2SiO5 (RE = Gd, Y, Er) environmental barrier coatings. J Mater Sci Technol 2021, 85: 141-151.
[151]
Cipitria A, Golosnoy IO, Clyne TW. A sintering model for plasma-sprayed zirconia TBCs. Part I: Free-standing coatings. Acta Mater 2009, 57: 980-992.
[152]
Chi WG, Sampath S, Wang H. Microstructure-thermal conductivity relationships for plasma-sprayed yttria-stabilized zirconia coatings. J Am Ceram Soc 2008, 91: 2636-2645.
[153]
Marple BR, Lima RS, Moreau C, et al. Yttria-stabilized zirconia thermal barriers sprayed using N2-H2 and Ar-H2 plasmas: Influence of processing and heat treatment on coating properties. J Therm Spray Technol 2007, 16: 791-797.
[154]
Tan Y, Longtin JP, Sampath S, et al. Effect of the starting microstructure on the thermal properties of as-sprayed and thermally exposed plasma-sprayed YSZ coatings. J Am Ceram Soc 2009, 92: 710-716.
[155]
Thompson JA, Clyne TW. The effect of heat treatment on the stiffness of zirconia top coats in plasma-sprayed TBCs. Acta Mater 2001, 49: 1565-1575.
[156]
Lima RS, Kruger SE, Lamouche G, et al. Elastic modulus measurements via laser-ultrasonic and Knoop indentation techniques in thermally sprayed coatings. J Therm Spray Technol 2005, 14: 52-60.
[157]
Guo SQ, Kagawa Y. Young’s moduli of zirconia top-coat and thermally grown oxide in a plasma-sprayed thermal barrier coating system. Scripta Mater 2004, 50: 1401-1406.
[158]
Tan Y, Shyam A, Choi WB, et al. Anisotropic elastic properties of thermal spray coatings determined via resonant ultrasound spectroscopy. Acta Mater 2010, 58: 5305-5315.
[159]
Liu T, Chen X, Yang GJ, et al. Properties evolution of plasma-sprayed La2Zr2O7 coating induced by pore structure evolution during thermal exposure. Ceram Int 2016, 42: 15485-15492.
[160]
Li GR, Xie H, Yang GJ, et al. A comprehensive sintering mechanism for TBCs—Part I: An overall evolution with two-stage kinetics. J Am Ceram Soc 2017, 100: 2176-2189.
[161]
Wang LS, Tang CH, Dong H, et al. Dominant effects of 2D pores on mechanical behaviors of plasma sprayed ceramic coatings during thermal exposure. Ceram Int 2020, 46: 6774-6781.
[162]
Yang GJ, Li CJ, Li CX, et al. Improvement of adhesion and cohesion in plasma-sprayed ceramic coatings by heterogeneous modification of nonbonded lamellar interface using high strength adhesive infiltration. J Therm Spray Technol 2013, 22: 36-47.
[163]
Li GR, Wang LS, Yang GJ, et al. Combined effect of internal and external factors on sintering kinetics of plasma-sprayed thermal barrier coatings. J Eur Ceram Soc 2019, 39: 1860-1868.
[164]
Liu T, Luo XT, Chen X, et al. Morphology and size evolution of interlamellar two-dimensional pores in plasma-sprayed La2Zr2O7 coatings during thermal exposure at 1300 ℃. J Therm Spray Technol 2015, 24: 739-748.
[165]
Li GR, Xie H, Yang GJ, et al. A comprehensive sintering mechanism for TBCs—Part II: Multiscale multipoint interconnection-enhanced initial kinetics. J Am Ceram Soc 2017, 100: 4240-4251.
[166]
Li CJ, Ohmori A, McPherson R. The relationship between microstructure and Young’s modulus of thermally sprayed ceramic coatings. J Mater Sci 1997, 32: 997-1004.
[167]
Wang LS, Wei ZY, Cheng B, et al. Gradient stiffening induced interfacial cracking and strain tolerant design in thermal barrier coatings. Ceram Int 2020, 46: 2355-2364.
[168]
Li GR, Tang CH, Yang GJ. Dynamic-stiffening-induced aggravated cracking behavior driven by metal-substrate-constraint in a coating/substrate system. J Mater Sci Technol 2021, 65: 154-163.
[169]
Liu MJ, Zhang G, Lu YH, et al. Plasma spray-physical vapor deposition toward advanced thermal barrier coatings: A review. Rare Metals 2020, 39: 479-497.
[170]
Chen C, Guo HB, Gong SK, et al. Sintering of electron beam physical vapor deposited thermal barrier coatings under flame shock. Ceram Int 2013, 39: 5093-5102.
[171]
Guo HB, Kuroda S, Murakami H. Microstructures and properties of plasma-sprayed segmented thermal barrier coatings. J Am Ceram Soc 2006, 89: 1432-1439.
[172]
Chevalier J, Gremillard L, Virkar AV, et al. The tetragonal-monoclinic transformation in zirconia: Lessons learned and future trends. J Am Ceram Soc 2009, 92: 1901-1920.
[173]
Fadda G, Zanzotto G, Colombo L. First-principles study of the effect of pressure on the five zirconia polymorphs. I. Structural, vibrational, and thermoelastic properties. Phys Rev B 2010, 82: 064105.
[174]
Béchade J-L, Brenner R, Goudeau P, et al. Determination of residual stresses in a zirconia layer by X-ray diffraction and by a micromechanical approach: Thermoelastic anisotropy effect. Rev Met Paris 2003, 100: 1151-1156.
[175]
Sibil A, Douillard T, Cayron C, et al. Microcracking of high zirconia refractories after t→m phase transition during cooling: An EBSD study. J Eur Ceram Soc 2011, 31: 1525-1531.
[176]
Hallmann L, Ulmer P, Reusser E, et al. Effect of blasting pressure, abrasive particle size and grade on phase transformation and morphological change in dental zirconia surface. Surf Coat Technol 2012, 206: 4293-4302.
[177]
Saemi H, Rastegari S, Sarpoolaky H, et al. Oxidation resistance of double-ceramic-layered thermal barrier coating system with an intermediate Al2O3-YAG layer. J Therm Spray Technol 2021, 30: 1049-1058.
[178]
Cao YP, Ning XJ, Wang QS. Thermal shock behavior of Ba(Mg1/3Ta2/3)O3-YSZ double-ceramic-layer thermal barrier coatings prepared by atmospheric plasma spraying. Surf Coat Technol 2021, 409: 126842.
[179]
Schulz U. Phase transformation in EB-PVD yttria partially stabilized zirconia thermal barrier coatings during annealing. J Am Ceram Soc 2000, 83: 904-910.
[180]
Mamivand M, Asle Zaeem M, El Kadiri H, et al. Phase field modeling of the tetragonal-to-monoclinic phase transformation in zirconia. Acta Mater 2013, 61: 5223-5235.
[181]
Chevalier J, Liens A, Reveron H, et al. Forty years after the promise of «ceramic steel?»: Zirconia-based composites with a metal-like mechanical behavior. J Am Ceram Soc 2020, 103: 1482-1513.
[182]
Chai YJ, Lin C, Wang X, et al. Study on stress development in the phase transition layer of thermal barrier coatings. Materials 2016, 9: 773.
[183]
Sun YL, Li JG, Zhang WX, et al. Local stress evolution in thermal barrier coating system during isothermal growth of irregular oxide layer. Surf Coat Technol 2013, 216: 237-250.
[184]
Fan XL, Zhang WX, Wang TJ, et al. The effect of thermally grown oxide on multiple surface cracking in air plasma sprayed thermal barrier coating system. Surf Coat Technol 2012, 208: 7-13.
[185]
Zhang WX, Fan XL, Wang TJ. The surface cracking behavior in air plasma sprayed thermal barrier coating system incorporating interface roughness effect. Appl Surf Sci 2011, 258: 811-817.
[186]
Xie F, Sun YL, Li DJ, et al. Modelling of catastrophic stress development due to mixed oxide growth in thermal barrier coatings. Ceram Int 2019, 45: 11353-11361.
[187]
Lv BW, Xie H, Xu R, et al. Effects of sintering and mixed oxide growth on the interface cracking of air-plasma-sprayed thermal barrier coating system at high temperature. Appl Surf Sci 2016, 360: 461-469.
[188]
Sait F, Gurses E, Aslan O. Modeling and simulation of coupled phase transformation and stress evolution in thermal barrier coatings. Int J Plast 2020, 134: 102790.
[189]
Liu PF, Jiang P, Sun YL, et al. Numerical analysis of stress evolution in thermal barrier coating system during two-stage growth of heterogeneous oxide. Ceram Int 2021, 47: 14311-14319.
[190]
Xie F, Li DJ, Zhang WX. Long-term failure mechanisms of thermal barrier coatings in heavy-duty gas turbines. Coatings 2020, 10: 1022.
[191]
Wang X, Atkinson A, Chirivì L, et al. Evolution of stress and morphology in thermal barrier coatings. Surf Coat Technol 2010, 204: 3851-3857.
[192]
El Kadiri H, Utegulov ZN, Khafizov M, et al. Transformations and cracks in zirconia films leading to breakaway oxidation of Zircaloy. Acta Mater 2013, 61: 3923-3935.
[193]
Wu LT, Wu RT, Xiao P, et al. A prominent driving force for the spallation of thermal barrier coatings: Chemistry dependent phase transformation of the bond coat. Acta Mater 2017, 137: 22-35.
[194]
Zhang BY, Yang GJ, Li CX, et al. Non-parabolic isothermal oxidation kinetics of low pressure plasma sprayed MCrAlY bond coat. Appl Surf Sci 2017, 406: 99-109.
[195]
Meng GH, Liu H, Xu PY, et al. Superior oxidation resistant MCrAlY bond oats prepared by controlled atmosphere heat treatment. Corros Sci 2020, 170: 108653.
[196]
Meng GH, Liu H, Liu MJ, et al. Large-grain α-Al2O3 enabling ultra-high oxidation-resistant MCrAlY bond coats by surface pre-agglomeration treatment. Corros Sci 2020, 163: 108275.
[197]
Meng GH, Liu H, Liu MJ, et al. Highly oxidation resistant MCrAlY bond coats prepared by heat treatment under low oxygen content. Surf Coat Technol 2019, 368: 192-201.
[198]
Meng GH, Zhang BY, Liu H, et al. Highly oxidation resistant and cost effective MCrAlY bond coats prepared by controlled atmosphere heat treatment. Surf Coat Technol 2018, 347: 54-65.
[199]
Sun YL, Zhang WX, Li JG, et al. Local stress around cap-like portions of anisotropically and nonuniformly grown oxide layer in thermal barrier coating system. J Mater Sci 2013, 48: 5962-5982.
[200]
Ding J, Li FX, Kang KJ. Numerical simulation of displacement instabilities of surface grooves on an alumina forming alloy during thermal cycling oxidation. J Mech Sci Technol 2009, 23: 2308-2319.
[201]
Osorio JD, Giraldo J, Hernández JC, et al. Diffusion-reaction of aluminum and oxygen in thermally grown Al2O3 oxide layers. Heat Mass Transf 2014, 50: 483-492.
[202]
Chen WR, Archer R, Huang X, et al. TGO growth and crack propagation in a thermal barrier coating. J Therm Spray Technol 2008, 17: 858-864.
[203]
Ali MS, Song SH, Xiao P. Degradation of thermal barrier coatings due to thermal cycling up to 1150 ℃. J Mater Sci 2002, 37: 2097-2102.
[204]
Chen WR, Irissou E, Wu X, et al. The oxidation behavior of TBC with cold spray CoNiCrAlY bond coat. J Therm Spray Technol 2011, 20: 132-138.
[205]
Eriksson R, Gupta M, Broitman E, et al. Stresses and cracking during chromia-spinel-NiO cluster formation in TBC systems. J Therm Spray Technol 2015, 24: 1002-1014.
[206]
Naumenko D, Shemet V, Singheiser L, et al. Failure mechanisms of thermal barrier coatings on MCrAlY-type bondcoats associated with the formation of the thermally grown oxide. J Mater Sci 2009, 44: 1687-1703.
[207]
Gupta M, Skogsberg K, Nylén P. Influence of topcoat-bondcoat interface roughness on stresses and lifetime in thermal barrier coatings. J Therm Spray Technol 2014, 23: 170-181.
[208]
Chen WR, Wu X, Dudzinski D. Influence of thermal cycle frequency on the TGO growth and cracking behaviors of an APS-TBC. J Therm Spray Technol 2012, 21: 1294-1299.
[209]
Xiao BJ, Robertson T, Huang X, et al. Fracture performance and crack growth prediction of SPS TBCs in isothermal experiments by crack numbering density. Ceram Int 2020, 46: 2682-2692.
[210]
Li Y, Li CJ, Yang GJ, et al. Thermal fatigue behavior of thermal barrier coatings with the MCrAlY bond coats by cold spraying and low-pressure plasma spraying. Surf Coat Technol 2010, 205: 2225-2233.
[211]
Liu JH, Liu YB, Liu L, et al. Submodeling method to study the residual stress of TBCs near the interfacial asperity on a vane. Eng Fail Anal 2021, 122: 105220.
[212]
Jiang P, Yang LY, Sun YL, et al. Local residual stress evolution of highly irregular thermally grown oxide layer in thermal barrier coatings. Ceram Int 2021, 47: 10990-10995.
[213]
Hu ZC, Wang L, Zhuang MX, et al. Influence of internal oxidation of the bond-coat on the residual stress around the TGO and failure modes of the APS-TBCs: A finite element simulation study. Ceram Int 2021, 47: 5364-5373.
[214]
Rabiei A, Evans AG. Failure mechanisms associated with the thermally grown oxide in plasma-sprayed thermal barrier coatings. Acta Mater 2000, 48: 3963-3976.
[215]
Dong H, Yang GJ, Li CX, et al. Effect of TGO thickness on thermal cyclic lifetime and failure mode of plasma-sprayed TBCs. J Am Ceram Soc 2014, 97: 1226-1232.
[216]
Weng WX, Zheng ZH, Li Q. Cracking evolution of atmospheric plasma-sprayed YSZ thermal barrier coatings subjected to isothermal heat treatment. Surf Coat Technol 2020, 402: 125924.
[217]
Huang YP, Wei ZY, Cai HN, et al. The effects of TGO growth stress and creep rate on TC/TGO interface cracking in APS thermal barrier coatings. Ceram Int 2021, 47: 24760-24769.
[218]
Shen Q, Yang L, Zhou YC, et al. Models for predicting TGO growth to rough interface in TBCs. Surf Coat Technol 2017, 325: 219-228.
[219]
Xu HB, Gong SK, Zhang Y, et al. Experimental and computational study on hot fatigue process of thermal barrier coatings by EB-PVD. Intermetallics 2005, 13: 315-322.
[220]
Ebach-Stahl A, Schulz U, Swadźba R, et al. Lifetime improvement of EB-PVD 7YSZ TBCs by doping of Hf or Zr in NiCoCrAlY bond coats. Corros Sci 2021, 181: 109205.
[221]
Shi JQ, Zhang TB, Sun B, et al. Isothermal oxidation and TGO growth behavior of NiCoCrAlY-YSZ thermal barrier coatings on a Ni-based superalloy. J Alloys Compd 2020, 844: 156093.
[222]
Chen WR, Wu X, Marple BR, et al. TGO growth behaviour in TBCs with APS and HVOF bond coats. Surf Coat Technol 2008, 202: 2677-2683.
[223]
Dong H, Yang G-J, Luo X-T, et al. Effect of mixed oxides on thermal cyclic lifetime of plasma-sprayed thermal barrier coatings. China Surf Eng 2015, 28: 21-28. (in Chinese)
[224]
Dong H, Yao JT, Li X, et al. The sintering behavior of plasma-sprayed YSZ coating over the delamination crack in low temperature environment. Ceram Int 2018, 44: 3326-3332.
[225]
Wang JL, Chen MH, Yang LL, et al. Nanocrystalline coatings on superalloys against high temperature oxidation: A review. Corros Commun 2021, 1: 58-69.
[226]
Yang YF, Jiang CY, Bao ZB, et al. Effect of aluminisation characteristics on the microstructure of single phase β-(Ni,Pt)Al coating and the isothermal oxidation behaviour. Corros Sci 2016, 106: 43-54.
[227]
Yang YF, Jiang CY, Yao HR, et al. Preparation and enhanced oxidation performance of a Hf-doped single-phase Pt-modified aluminide coating. Corros Sci 2016, 113: 17-25.
[228]
Bao ZB, Wang QM, Li WZ, et al. Corrosion behaviour of AIP NiCoCrAlYSiB coating in salt spray tests. Corros Sci 2008, 50: 847-855.
[229]
Bao ZB, Wang QM, Li WZ, et al. Preparation and hot corrosion behaviour of an Al-gradient NiCoCrAlYSiB coating on a Ni-base superalloy. Corros Sci 2009, 51: 860-867.
[230]
Narita T. Diffusion barrier coating system concept for high temperature applications. Can Metall Quart 2011, 50: 278-290.
[231]
Liang JJ, Matsumoto K, Kawagishi K, et al. Morphological evolution of thermal barrier coatings with equilibrium (EQ) and NiCoCrAlY bond coats during thermal cycling. Surf Coat Technol 2012, 207: 413-420.
[232]
Mercer C, Kawagishi K, Tomimatsu T, et al. A comparative investigation of oxide formation on EQ (equilibrium) and NiCoCrAlY bond coats under stepped thermal cycling. Surf Coat Technol 2011, 205: 3066-3072.
[233]
Wang JL, Chen MH, Yang LL, et al. Comparative study of oxidation and interdiffusion behavior of AIP NiCrAlY and sputtered nanocrystalline coatings on a nickel-based single-crystal superalloy. Corros Sci 2015, 98: 530-540.
[234]
Yang LL, Chen MH, Wang JL, et al. Diffusion of Ta and its influence on oxidation behavior of nanocrystalline coatings with different Ta, Y and Al contents. Corros Sci 2017, 126: 344-355.
[235]
Ghasemi R, Valefi Z. The effect of the Re-Ni diffusion barrier on the adhesion strength and thermal shock resistance of the NiCoCrAlY coating. Surf Coat Technol 2018, 344: 359-372.
[236]
Narita T, Thosin KZ, Fengqun L, et al. Development of Re-based diffusion barrier coatings on nickel based superalloys. Mater Corros 2005, 56: 923-929.
[237]
Li HQ, Wang QM, Jiang SM, et al. Ion-plated Al-Al2O3 films as diffusion barriers between NiCrAlY coating and orthorhombic-Ti2AlNb alloy. Corros Sci 2010, 52: 1668-1674.
[238]
Li WZ, Wang QM, Gong J, et al. Interdiffusion reaction in the CrN interlayer in the NiCrAlY/CrN/DSM11 system during thermal treatment. Appl Surf Sci 2009, 255: 8190-8193.
[239]
Guo CA, Wang W, Cheng YX, et al. Yttria partially stabilised zirconia as diffusion barrier between NiCrAlY and Ni-base single crystal René N5 superalloy. Corros Sci 2015, 94: 122-128.
[240]
Yao HR, Bao ZB, Shen ML, et al. A magnetron sputtered microcrystalline β-NiAl coating for SC superalloys. Part II. Effects of a NiCrO diffusion barrier on oxidation behavior at 1100 ℃. Appl Surf Sci 2017, 407: 485-494.
[241]
Cheng YX, Wang W, Zhu SL, et al. Arc ion plated-Cr2O3 intermediate film as a diffusion barrier between NiCrAlY and γ-TiAl. Intermetallics 2010, 18: 736-739.
[242]
Sim JK, Lee SK, Kim JS, et al. Efficiency enhancement of CIGS compound solar cell fabricated using homomorphic thin Cr2O3 diffusion barrier formed on stainless steel substrate. Appl Surf Sci 2016, 389: 645-650.
[243]
Wang CX, Chen W, Chen MH, et al. Corrosion behavior and elements interdiffusion between a Ni coating and GH3535 alloy with and without a CrN barrier in molten fluoride salts. J Nucl Mater 2019, 514: 348-357.
[244]
Ren P, Zhu SL, Wang FH. TEM study of the evolution of sputtered Ni + CrAlYSiHfN nanocomposite coating with an AlN diffusion barrier at high temperature. Surf Coat Technol 2016, 286: 262-267.
[245]
Zhu LJ, Zhu SL, Wang FH. Preparation and oxidation behaviour of nanocrystalline Ni + CrAlYSiN composite coating with AlN diffusion barrier on Ni-based superalloy K417. Corros Sci 2012, 60: 265-274.
[246]
Liu H, Li S, Jiang CY, et al. Preparation and oxidation performance of a low-diffusion Pt-modified aluminide coating with Re-base diffusion barrier. Corros Sci 2020, 168: 108582.
[247]
Levi CG, Hutchinson JW, Vidal-Sétif MH, et al. Environmental degradation of thermal-barrier coatings by molten deposits. MRS Bull 2012, 37: 932-941.
[248]
Wang YH, Ma Z, Liu L, et al. Reaction products of Sm2Zr2O7 with calcium-magnesium-aluminum-silicate (CMAS) and their evolution. J Adv Ceram 2021, 10: 1389-1397.
[249]
Giehl C, Brooker RA, Marxer H, et al. An experimental simulation of volcanic ash deposition in gas turbines and implications for jet engine safety. Chem Geol 2017, 461: 160-170.
[250]
Ghoshal A, Murugan M, Walock MJ, et al. Molten particulate impact on tailored thermal barrier coatings for gas turbine engine. J Eng Gas Turbines Power 2017, 140: 022601.
[251]
Crosby JM, Lewis S, Bons JP, et al. Effects of particle size, gas temperature and metal temperature on high pressure turbine deposition in land based gas turbines from various synfuels. In: Proceedings of the Turbo Expo: Power for Land, Sea and Air, Montreal, Canada, 2007: 1365-1376.
DOI
[252]
Shinozaki M, Roberts KA, van de Goor B, et al. Deposition of ingested volcanic ash on surfaces in the turbine of a small jet engine. Adv Eng Mater 2013, 15: 986-994.
[253]
Yang SJ, Song WJ, Lavallee Y, et al. Dynamic spreading of re-melted volcanic ash bead on thermal barrier coatings. Corros Sci 2020, 170: 108659.
[254]
Kang YX, Bai Y, Bao CG, et al. Defects/CMAS corrosion resistance relationship in plasma sprayed YPSZ coating. J Alloys Compd 2017, 694: 1320-1330.
[255]
Liu T, Yao SW, Wang LS, et al. Plasma-sprayed thermal barrier coatings with enhanced splat bonding for CMAS and corrosion protection. J Therm Spray Technol 2016, 25: 213-221.
[256]
Shan X, Cai HY, Luo LR, et al. Influence of pore characteristics of air plasma sprayed thermal barrier coatings on calcia-magnesia-alumino-silicate (CMAS) attack behavior. Corros Sci 2021, 190: 109636.
[257]
Shan X, Luo LR, Chen WF, et al. Pore filling behavior of YSZ under CMAS attack: Implications for designing corrosion-resistant thermal barrier coatings. J Am Ceram Soc 2018, 101: 5756-5770.
[258]
Shan X, Chen WF, Yang LX, et al. Pore filling behavior of air plasma spray thermal barrier coatings under CMAS attack. Corros Sci 2020, 167: 108478.
[259]
Krämer S, Yang J, Levi CG, et al. Thermochemical interaction of thermal barrier coatings with molten CaO-MgO-Al2O3-SiO2 (CMAS) deposits. J Am Ceram Soc 2006, 89: 3167-3175.
[260]
Garces HF, Senturk BS, Padture NP. In situ Raman spectroscopy studies of high-temperature degradation of thermal barrier coatings by molten silicate deposits. Scripta Mater 2014, 76: 29-32.
[261]
Witz G, Shklover V, Steurer W, et al. High-temperature interaction of yttria stabilized zirconia coatings with CaO-MgO-Al2O3-SiO2 (CMAS) deposits. Surf Coat Technol 2015, 265: 244-249.
[262]
Morelli S, Testa V, Bolelli G, et al. CMAS corrosion of YSZ thermal barrier coatings obtained by different thermal spray processes. J Eur Ceram Soc 2020, 40: 4084-4100.
[263]
Holgate CS, Seward GGE, Ericks AR, et al. Dissolution and diffusion kinetics of yttria-stabilized zirconia into molten silicates. J Eur Ceram Soc 2021, 41: 1984-1994.
[264]
Boissonnet G, Chalk C, Nicholls J, et al. Thermal insulation of CMAS (calcium-magnesium-alumino-silicates)-attacked plasma-sprayed thermal barrier coatings. J Eur Ceram Soc 2020, 40: 2042-2049.
[265]
Mercer C, Faulhaber S, Evans AG, et al. A delamination mechanism for thermal barrier coatings subject to calcium-magnesium-alumino-silicate (CMAS) infiltration. Acta Mater 2005, 53: 1029-1039.
[266]
Mack DE, Wobst T, Jarligo MOD, et al. Lifetime and failure modes of plasma sprayed thermal barrier coatings in thermal gradient rig tests with simultaneous CMAS injection. Surf Coat Technol 2017, 324: 36-47.
[267]
Shan X, Zou ZH, Gu LJ, et al. Buckling failure in air-plasma sprayed thermal barrier coatings induced by molten silicate attack. Scripta Mater 2016, 113: 71-74.
[268]
Drexler JM, Chen CH, Gledhill AD, et al. Plasma sprayed gadolinium zirconate thermal barrier coatings that are resistant to damage by molten Ca-Mg-Al-silicate glass. Surf Coat Technol 2012, 206: 3911-3916.
[269]
Gao LH, Guo HB, Gong SK, et al. Plasma-sprayed La2Ce2O7 thermal barrier coatings against calcium-magnesium-alumina-silicate penetration. J Eur Ceram Soc 2014, 34: 2553-2561.
[270]
Ma W, Gong SK, Li HF, et al. Novel thermal barrier coatings based on La2Ce2O7/8YSZ double-ceramic-layer systems deposited by electron beam physical vapor deposition. Surf Coat Technol 2008, 202: 2704-2708.
[271]
Yin BB, Xia J, Liu WW, et al. Experimental study on CMAS corrosion resistance performance of La2Ce2O7/YSZ thermal barrier coatings. J Xiangtan University Nat Sci 2020, 42: 62-72. (in Chinese)
[272]
Dolmaire A, Goutier S, Joulia A, et al. Experimental study of the impact of substrate shape and tilting on particle velocity in suspension plasma spraying. J Therm Spray Technol 2020, 29: 358-367.
[273]
Yin JN, Zhang X, Feng JL, et al. Effect of powder composition upon plasma spray-physical vapor deposition of 8YSZ columnar coating. Ceram Int 2020, 46: 15867-15875.
[274]
Danek JR GJ. State-of-the-art survey on hot corrosion in marine gas turbine engines. Nav Eng J 1965, 77: 859-869.
[275]
Shifler DA. Hot corrosion: A modification of reactants causing degradation. Mater High Temp 2018, 35: 225-235.
[276]
Kosieniak E, Biesiada K, Kaczorowski J, et al. Corrosion failures in gas turbine hot components. J Fail Anal Prev 2012, 12: 330-337.
[277]
Gurrappa I. Identification of hot corrosion resistant MCrAlY based bond coatings for gas turbine engine applications. Surf Coat Technol 2001, 139: 272-283.
[278]
Sreedhar G, Raja VS. Hot corrosion of YSZ/Al2O3 dispersed NiCrAlY plasma-sprayed coatings in Na2SO4-10 wt.% NaCl melt. Corros Sci 2010, 52: 2592-2602.
[279]
O’Dowd CD, de Leeuw G. Marine aerosol production: A review of the current knowledge. Phil Trans R Soc A 2007, 365: 1753-1774.
[280]
Pettit F. Hot corrosion of metals and alloys. Oxid Met 2011, 76: 1-21.
[281]
Mauer G, Hospach A, Vaßen R. Process development and coating characteristics of plasma spray-PVD. Surf Coat Technol 2013, 220: 219-224.
[282]
Zhang X-F, Zhou K-S, Song J-B, et al. Deposition and CMAS corrosion mechanism of 7YSZ thermal barrier coatings prepared by plasma spray-physical vapor deposition. J Inorg Mater 2015, 30: 287-293. (in Chinese)
[283]
Ozgurluk Y, Doleker KM, Karaoglanli AC. Hot corrosion behavior of YSZ, Gd2Zr2O7 and YSZ/Gd2Zr2O7 thermal barrier coatings exposed to molten sulfate and vanadate salt. Appl Surf Sci 2018, 438: 96-113.
[284]
Jonnalagadda KP, Mahade S, Curry N, et al. Hot corrosion mechanism in multilayer suspension plasma sprayed Gd2Zr2O7/YSZ thermal barrier coatings in the presence of V2O5 + Na2SO4. J Therm Spray Technol 2017, 26: 140-149.
[285]
Zhu C, Wang YG, An LN, et al. Microstructure and oxidation behavior of conventional and pseudo graded NiCrAlY/YSZ thermal barrier coatings produced by supersonic air plasma spraying process. Surf Coat Technol 2015, 272: 121-128.
[286]
Kakuda TR, Levi CG, Bennett TD. The thermal behavior of CMAS-infiltrated thermal barrier coatings. Surf Coat Technol 2015, 272: 350-356.
[287]
Poerschke DL, Levi CG. Effects of cation substitution and temperature on the interaction between thermal barrier oxides and molten CMAS. J Eur Ceram Soc 2015, 35: 681-691.
[288]
Evans AG, Fleck NA, Faulhaber S, et al. Scaling laws governing the erosion and impact resistance of thermal barrier coatings. Wear 2006, 260: 886-894.
[289]
Fan J-F, Zhang X-F, Zhou K-S, et al. Influence of Al-modification on CMAS corrosion resistance of PS-PVD 7YSZ thermal barrier coatings. J Inorg Mater 2019, 34: 938-946. (in Chinese)
[290]
Zhang XF, Zhou KS, Liu M, et al. CMAS corrosion and thermal cycle of Al-modified PS-PVD environmental barrier coating. Ceram Int 2018, 44: 15959-15964.
[291]
Zhang XF, Liu M, Li H, et al. Structural evolution of Al-modified PS-PVD 7YSZ TBCs in thermal cycling. Ceram Int 2019, 45: 7560-7567.
[292]
Hua YF, Pan W, Li ZX, et al. Research progress of hot corrosion-resistance for thermal barrier coatings, Rare Metal Mat Eng 2013, 42: 1976-1980. (in Chinese)
[293]
Costa GCC, Zhu DM, Kulis MJ, et al. Reactivity between rare-earth oxides based thermal barrier coatings and a silicate melt. J Am Ceram Soc 2018, 101: 3674-3693.
[294]
Teja Pasupuleti K, Manikanta Dunna U, Ghosh S, et al. Synthesis and studies on partially stabilized zirconia and rare-earth zirconate pyrochlore structured multilayered coatings. Mater Today Proc 2020, 22: 1244-1252.
[295]
Jana P, Jayan PS, Mandal S, et al. Hot corrosion behaviour of rare-earth magnesium hexaaluminate based thermal barrier coatings under molten sulphate-vanadate salts. Surf Coat Technol 2017, 322: 108-119.
[296]
Shen ZY, Liu Z, Huang ZY, et al. Thermal shock life and failure behaviors of La2Zr2O7/YSZ, La2Ce2O7/YSZ and Gd2Zr2O7/YSZ DCL TBCs by EB-PVD. Mater Charact 2021, 173: 110923.
[297]
Liu Y, Bai Y, Li EB, et al. Preparation and characterization of SrZrO3-La2Ce2O7 composite ceramics as a thermal barrier coating material. Mater Chem Phys 2020, 247: 122904.
[298]
Stott FH, de Wet DJ, Taylor R. Degradation of thermal-barrier coatings at very high temperatures. MRS Bull 1994, 19: 46-49.
[299]
Evans AG, Hutchinson JW. The mechanics of coating delamination in thermal gradients. Surf Coat Technol 2007, 201: 7905-7916.
[300]
Jackson RW, Zaleski EM, Poerschke DL, et al. Interaction of molten silicates with thermal barrier coatings under temperature gradients. Acta Mater 2015, 89: 396-407.
[301]
Cai ZW, Jiang JS, Wang WZ, et al. CMAS penetration-induced cracking behavior in the ceramic top coat of APS TBCs. Ceram Int 2019, 45: 14366-14375.
[302]
Krämer S, Faulhaber S, Chambers M, et al. Mechanisms of cracking and delamination within thick thermal barrier systems in aeroengines subject to calcium-magnesium-alumino-silicate (CMAS) penetration. Mater Sci Eng A 2008, 490: 26-35.
[303]
Yang L, Yang J, Xia J, et al. Characterization of the strain in the thermal barrier coatings caused by molten CaO-MgO-Al2O3-SiO2 using a digital image correlation technique. Surf Coat Technol 2017, 322: 1-9.
[304]
Jamali H, Mozafarinia R, Shoja-Razavi R, et al. Comparison of hot corrosion behaviors of plasma-sprayed nanostructured and conventional YSZ thermal barrier coatings exposure to molten vanadium pentoxide and sodium sulfate. J Eur Ceram Soc 2014, 34: 485-492.
[305]
Xu ZH, He LM, Mu RD, et al. Hot corrosion behavior of rare earth zirconates and yttria partially stabilized zirconia thermal barrier coatings. Surf Coat Technol 2010, 204: 3652-3661.
[306]
Guo L, Li MZ, Ye FX. Comparison of hot corrosion resistance of Sm2Zr2O7 and (Sm0.5Sc0.5)2Zr2O7 ceramics in Na2SO4 + V2O5 molten salt. Ceram Int 2016, 42: 13849-13854.
[307]
Shifler DA. The increasing complexity of corrosion in gas turbines. In: Proceedings of the Turbo Expo: Power for Land, Sea and Air, Pheonix, USA, 2019: GT2019-90111.
DOI
[308]
Shifler DA, Choi SR. CMAS effects on ship gas-turbine components/materials. In: Proceedings of the Turbo Expo: Power for Land, Sea and Air, Oslo, Norway, 2018: GT2018-75865.
DOI
[309]
Guo L, Xin H, Hu CW. Comparison of NaVO3 + CMAS mixture and CMAS corrosion to thermal barrier coatings. Corros Sci 2020, 177: 108968.
[310]
Drexler JM, Shinoda K, Ortiz AL, et al. Air-plasma-sprayed thermal barrier coatings that are resistant to high-temperature attack by glassy deposits. Acta Mater 2010, 58: 6835-6844.
[311]
Wiesner VL, Bansal NP. Crystallization kinetics of calcium-magnesium aluminosilicate (CMAS) glass. Surf Coat Technol 2014, 259: 608-615.
[312]
Guo L, Xin H, Li YY, et al. Self-crystallization characteristics of calcium-magnesium-alumina-silicate (CMAS) glass under simulated conditions for thermal barrier coating applications. J Eur Ceram Soc 2020, 40: 5683-5691.
[313]
Wang L, Guo L, Li ZM, et al. Protectiveness of Pt and Gd2Zr2O7 layers on EB-PVD YSZ thermal barrier coatings against calcium-magnesium-alumina-silicate (CMAS) attack. Ceram Int 2015, 41: 11662-11669.
[314]
Guo L, Yan Z, Wang XH, et al. Ti2AlC MAX phase for resistance against CMAS attack to thermal barrier coatings. Ceram Int 2019, 45: 7627-7634.
[315]
Yan Z, Guo L, Zhang Z, et al. Versatility of potential protective layer material Ti2AlC on resisting CMAS corrosion to thermal barrier coatings. Corros Sci 2020, 167: 108532.
[316]
Yan Z, Guo L, Li ZH, et al. Effects of laser glazing on CMAS corrosion behavior of Y2O3 stabilized ZrO2 thermal barrier coatings. Corros Sci 2019, 157: 450-461.
[317]
Habibi MH, Wang L, Liang JD, et al. An investigation on hot corrosion behavior of YSZ-Ta2O5 in Na2SO4 + V2O5 salt at 1100 ℃. Corros Sci 2013, 75: 409-414.
[318]
Nejati M, Rahimipour MR, Mobasherpour I. Evaluation of hot corrosion behavior of CSZ, CSZ/micro Al2O3 and CSZ/nano Al2O3 plasma sprayed thermal barrier coatings. Ceram Int 2014, 40: 4579-4590.
[319]
Loghman-Estarki MR, Razavi RS, Edris H, et al. Comparison of hot corrosion behavior of nanostructured ScYSZ and YSZ thermal barrier coatings. Ceram Int 2016, 42: 7432-7439.
[320]
Guo L, Zhang CL, Li MZ, et al. Hot corrosion evaluation of Gd2O3-Yb2O3 co-doped Y2O3 stabilized ZrO2 thermal barrier oxides exposed to Na2SO4 + V2O5 molten salt. Ceram Int 2017, 43: 2780-2785.
[321]
Guo L, Zhang CL, He Q, et al. Corrosion products evolution and hot corrosion mechanisms of REPO4 (RE = Gd, Nd, La) in the presence of V2O5 + Na2SO4 molten salt. J Eur Ceram Soc 2019, 39: 1496-1506.
[322]
Guo L, Xin H, Zhang Z, et al. Preparation of (Gd0.9Sc0.1)2Zr2O7/YSZ thermal barrier coatings and their corrosion resistance to V2O5 molten salt. Surf Coat Technol 2020, 389: 125677.
[323]
Guo L, Xin H, Zhang Z, et al. Microstructure modification of Y2O3 stabilized ZrO2 thermal barrier coatings by laser glazing and the effects on the hot corrosion resistance. J Adv Ceram 2020, 9: 232-242.
[324]
Guo L, Yan Z, Yu Y, et al. CMAS resistance characteristics of LaPO4/YSZ thermal barrier coatings at 1250 ℃-1350 ℃. Corros Sci 2019, 154: 111-122.
[325]
Chen XL, Zhao Y, Fan XZ, et al. Thermal cycling failure of new LaMgAl11O19/YSZ double ceramic top coat thermal barrier coating systems. Surf Coat Technol 2011, 205: 3293-3300.
[326]
Guo L, Yan Z, Li ZH, et al. GdPO4 as a novel candidate for thermal barrier coating applications at elevated temperatures. Surf Coat Technol 2018, 349: 400-406.
[327]
Guo L, Gao Y, Ye FX, et al. CMAS corrosion behavior and protection method of thermal barrier coatings for aeroengine. Acta Metall Sin 2021, 57: 1184-1198. (in Chinese)
[328]
Doleker KM, Ozgurluk Y, Ahlatci H, et al. Evaluation of oxidation and thermal cyclic behavior of YSZ, Gd2Zr2O7 and YSZ/Gd2Zr2O7 TBCs. Surf Coat Technol 2019, 371: 262-275.
[329]
Chen X, He MY, Spitsberg I, et al. Mechanisms governing the high temperature erosion of thermal barrier coatings. Wear 2004, 256: 735-746.
[330]
Fleck NA, Zisis T. The erosion of EB-PVD thermal barrier coatings: The competition between mechanisms. Wear 2010, 268: 1214-1224.
[331]
Zisis T, Fleck NA. The elastic-plastic indentation response of a columnar thermal barrier coating. Wear 2010, 268: 443-454.
[332]
Chen X, Wang R, Yao N, et al. Foreign object damage in a thermal barrier system: Mechanisms and simulations. Mater Sci Eng A 2003, 352: 221-231.
[333]
Wellman RG, Nicholls JR. Erosion, corrosion and erosion-corrosion of EB PVD thermal barrier coatings. Tribol Int 2008, 41: 657-662.
[334]
Crowell MW, Schaedler TA, Hazel BH, et al. Experiments and numerical simulations of single particle foreign object damage-like impacts of thermal barrier coatings. Int J Impact Eng 2012, 48: 116-124.
[335]
Karger M, Vaßen R, Stöver D. Atmospheric plasma sprayed thermal barrier coatings with high segmentation crack densities: Spraying process, microstructure and thermal cycling behavior. Surf Coat Technol 2011, 206: 16-23.
[336]
Cernuschi F, Lorenzoni L, Capelli S, et al. Solid particle erosion of thermal spray and physical vapour deposition thermal barrier coatings. Wear 2011, 271: 2909-2918.
[337]
Wellman RG, Nicholls JR. A review of the erosion of thermal barrier coatings. J Phys D Appl Phys 2007, 40: R293-R305.
[338]
Wellman RG, Nicholls JR, Murphy K. Effect of microstructure and temperature on the erosion rates and mechanisms of modified EB PVD TBCs. Wear 2009, 267: 1927-1934.
[339]
Janos BZ, Lugscheider E, Remer P. Effect of thermal aging on the erosion resistance of air plasma sprayed zirconia thermal barrier coating. Surf Coat Technol 1999, 113: 278-285.
[340]
Wellman RG, Deakin MJ, Nicholls JR. The effect of TBC morphology on the erosion rate of EB PVD TBCs. Wear 2005, 258: 349-356.
[341]
Wellman RG, Nicholls JR. On the effect of ageing on the erosion of EB-PVD TBCs. Surf Coat Technol 2004, 177-178: 80-88.
[342]
Zhu DM, Miller RA, Kuczmarski M. Development and life prediction of erosion resistant turbine low conductivity thermal barrier coatings. In: Proceedings of the 65th Annual Forum and Technology Display, Grapevine, USA, 2010: 20100011004.
[343]
Drexler JM, Aygun A, Li DS, et al. Thermal-gradient testing of thermal barrier coatings under simultaneous attack by molten glassy deposits and its mitigation. Surf Coat Technol 2010, 204: 2683-2688.
[344]
Drexler JM, Gledhill AD, Shinoda K, et al. Jet engine coatings for resisting volcanic ash damage. Adv Mater 2011, 23: 2419-2424.
[345]
Yan J, Karlsson AM, Bartsch M, et al. On stresses induced in a thermal barrier coating due to indentation testing. Comput Mater Sci 2009, 44: 1178-1191.
[346]
Chen X, Hutchinson JW, Evans AG. Simulation of the high temperature impression of thermal barrier coatings with columnar microstructure. Acta Mater 2004, 52: 565-571.
[347]
Ramanujam N, Nakamura T. Erosion mechanisms of thermally sprayed coatings with multiple phases. Surf Coat Technol 2009, 204: 42-53.
[348]
Chen L, Hu MY, Guo J, et al. Mechanical and thermal properties of RETaO4 (RE = Yb, Lu, Sc) ceramics with monoclinic-prime phase. J Mater Sci Technol 2020, 52: 20-28.
[349]
Zhao ZF, Chen H, Xiang HM, et al. High-entropy (Y0.2Nd0.2Sm0.2Eu0.2Er0.2)AlO3: A promising thermal/ environmental barrier material for oxide/oxide composites. J Mater Sci Technol 2020, 47: 45-51.
[350]
Cong LK, zhang SY, Gu SY, et al. Thermophysical properties of a novel high entropy hafnate ceramic. J Mater Sci Technol 2021, 85: 152-157.
[351]
Chen H, Zhao ZF, Xiang HM, et al. High entropy (Y0.2Yb0.2Lu0.2Eu0.2Er0.2)3Al5O12: A novel high temperature stable thermal barrier material. J Mater Sci Technol 2020, 48: 57-62.
[352]
Zhao ZF, Chen H, Xiang HM, et al. (Y0.25Yb0.25Er0.25Lu0.25)2(Zr0.5Hf0.5)2O7: A defective fluorite structured high entropy ceramic with low thermal conductivity and close thermal expansion coefficient to Al2O3. J Mater Sci Technol 2020, 39: 167-172.
[353]
Wei ZY, Cheng B, Wang J, et al. Extend the thermal cyclic lifetime of La2Zr2O7/YSZ DCL TBCs by reducing modulus design on a toughening ceramic surface. Surf Coat Technol 2019, 374: 134-143.
[354]
Cheng B, Wei ZY, Chen L, et al. Prolong the durability of La2Zr2O7/YSZ TBCs by decreasing the cracking driving force in ceramic coatings. J Eur Ceram Soc 2018, 38: 5482-5488.
[355]
Cheng B, Yang GJ, Zhang Q, et al. Gradient thermal cyclic behaviour of La2Zr2O7/YSZ DCL-TBCs with equivalent thermal insulation performance. J Eur Ceram Soc 2018, 38: 1888-1896.
[356]
Bakan E, Mack DE, Mauer G, et al. Porosity-property relationships of plasma-sprayed Gd2Zr2O7/YSZ thermal barrier coatings. J Am Ceram Soc 2015, 98: 2647-2654.
[357]
Ma W, Mack D, Malzbender J, et al. Yb2O3 and Gd2O3 doped strontium zirconate for thermal barrier coatings. J Eur Ceram Soc 2008, 28: 3071-3081.
[358]
Guo HB, Wang Y, Wang L, et al. Thermo-physical properties and thermal shock resistance of segmented La2Ce2O7/YSZ thermal barrier coatings. J Therm Spray Technol 2009, 18: 665-671.
[359]
Chen HF, Gao YF, Tao SY, et al. Thermophysical properties of lanthanum zirconate coating prepared by plasma spraying and the influence of post-annealing. J Alloys Compd 2009, 486: 391-399.
[360]
Rai AK, Schmitt MP, Bhattacharya RS, et al. Thermal conductivity and stability of multilayered thermal barrier coatings under high temperature annealing conditions. J Eur Ceram Soc 2015, 35: 1605-1612.
[361]
Cao XQ, Vassen R, Jungen W, et al. Thermal stability of lanthanum zirconate plasma-sprayed coating. J Am Ceram Soc 2001, 84: 2086-2090.
[362]
Wang L, Wang Y, Sun XG, et al. Thermal shock behavior of 8YSZ and double-ceramic-layer La2Zr2O7/8YSZ thermal barrier coatings fabricated by atmospheric plasma spraying. Ceram Int 2012, 38: 3595-3606.
[363]
Kokini K, DeJonge J, Rangaraj S, et al. Thermal shock of functionally graded thermal barrier coatings with similar thermal resistance. Surf Coat Technol 2002, 154: 223-231.
[364]
Chen HF, Liu Y, Gao YF, et al. Design, preparation, and characterization of graded YSZ/La2Zr2O7 thermal barrier coatings. J Am Ceram Soc 2010, 93: 1732-1740.
[365]
Zhang WW, Li GR, Zhang Q, et al. Multiscale pores in TBCs for lower thermal conductivity. J Therm Spray Technol 2017, 26: 1183-1197.
[366]
Cernuschi F, Ahmaniemi S, Vuoristo P, et al. Modelling of thermal conductivity of porous materials: Application to thick thermal barrier coatings. J Eur Ceram Soc 2004, 24: 2657-2667.
[367]
Wang L, Wang Y, Sun XG, et al. Influence of pores on the thermal insulation behavior of thermal barrier coatings prepared by atmospheric plasma spray. Mater Des 2011, 32: 36-47.
[368]
Dutton R, Wheeler R, Ravichandran KS, et al. Effect of heat treatment on the thermal conductivity of plasma-sprayed thermal barrier coatings. J Therm Spray Technol 2000, 9: 204-209.
[369]
Arai M, Ochiai H, Suidzu T. A novel low-thermal-conductivity plasma-sprayed thermal barrier coating controlled by large pores. Surf Coat Technol 2016, 285: 120-127.
[370]
Tjong SC, Chen H. Nanocrystalline materials and coatings. Mater Sci Eng R Rep 2004, 45: 1-88.
[371]
Fauchais P, Etchart-Salas R, Rat V, et al. Parameters controlling liquid plasma spraying: Solutions, sols, or suspensions. J Therm Spray Technol 2008, 17: 31-59.
[372]
Fauchais P, Montavon G, Lima RS, et al. Engineering a new class of thermal spray nano-based microstructures from agglomerated nanostructured particles, suspensions and solutions: An invited review. J Phys D Appl Phys 2011, 44: 093001.
[373]
Racek O, Berndt CC, Guru DN, et al. Nanostructured and conventional YSZ coatings deposited using APS and TTPR techniques. Surf Coat Technol 2006, 201: 338-346.
[374]
Zhou CG, Wang N, Wang ZB, et al. Thermal cycling life and thermal diffusivity of a plasma-sprayed nanostructured thermal barrier coating. Scripta Mater 2004, 51: 945-948.
[375]
Jordan EH, Jiang C, Roth J, et al. Low thermal conductivity yttria-stabilized zirconia thermal barrier coatings using the solution precursor plasma spray process. J Therm Spray Technol 2014, 23: 849-859.
[376]
Skoog A, Murphy J, Tomlinson T. Method for applying a plasma sprayed coating using liquid injection. U.S. patent 11 099 264, Oct. 2006.
[377]
Cipri F, Marra F, Pulci G, et al. Plasma sprayed composite coatings obtained by liquid injection of secondary phases. Surf Coat Technol 2009, 203: 2116-2124.
[378]
Joshi SV, Sivakumar G. Hybrid processing with powders and solutions: A novel approach to deposit composite coatings. J Therm Spray Technol 2015, 24: 1166-1186.
[379]
Lima RS, Marple BR. Toward highly sintering-resistant nanostructured ZrO2-7 wt.% Y2O3 coatings for TBC applications by employing differential sintering. J Therm Spray Technol 2008, 17: 846-852.
[380]
Ozturk A, Cetegen BM. Modeling of plasma assisted formation of precipitates in zirconium containing liquid precursor droplets. Mater Sci Eng A 2004, 384: 331-351.
[381]
Li GR, Yang GJ, Li CX, et al. Stage-sensitive microstructural evolution of nanostructured TBCs during thermal exposure. J Eur Ceram Soc 2018, 38: 3325-3332.
[382]
Zhang WW, Li GR, Zhang Q, et al. Bimodal TBCs with low thermal conductivity deposited by a powder-suspension co-spray process. J Mater Sci Technol 2018, 34: 1293-1304.
[383]
Zhang WW, Wei ZY, Zhang LY, et al. Low-thermal-conductivity thermal barrier coatings with a multi-scale pore design and sintering resistance following thermal exposure. Rare Met 2020, 39: 352-367.
[384]
Fauchais P, Rat V, Coudert JF, et al. Operating parameters for suspension and solution plasma-spray coatings. Surf Coat Technol 2008, 202: 4309-4317.
[385]
Bernard B, Quet A, Bianchi L, et al. Effect of suspension plasma-sprayed YSZ columnar microstructure and bond coat surface preparation on thermal barrier coating properties. J Therm Spray Technol 2017, 26: 1025-1037.
[386]
Curry N, VanEvery K, Snyder T, et al. Performance testing of suspension plasma sprayed thermal barrier coatings produced with varied suspension parameters. Coatings 2015, 5: 338-356.
[387]
Ganvir A, Curry N, Björklund S, et al. Characterization of microstructure and thermal properties of YSZ coatings obtained by axial suspension plasma spraying (ASPS). J Therm Spray Technol 2015, 24: 1195-1204.
[388]
Sokołowski P, Kozerski S, Pawłowski L, et al. The key process parameters influencing formation of columnar microstructure in suspension plasma sprayed zirconia coatings. Surf Coat Technol 2014, 260: 97-106.
[389]
Zhou DP, Guillon O, Vaßen R. Development of YSZ thermal barrier coatings using axial suspension plasma spraying. Coatings 2017, 7: 120.
[390]
Curry N, Tang ZL, Markocsan N, et al. Influence of bond coat surface roughness on the structure of axial suspension plasma spray thermal barrier coatings—Thermal and lifetime performance. Surf Coat Technol 2015, 268: 15-23.
[391]
Ekberg J, Ganvir A, Klement U, et al. The influence of heat treatments on the porosity of suspension plasma-sprayed yttria-stabilized zirconia coatings. J Therm Spray Technol 2018, 27: 391-401.
[392]
Movchan BA. Inorganic materials and coatings produced by EBPVD. Surf Eng 2006, 22: 35-46.
[393]
Yoshiya M, Wada K, Jang BK, et al. Computer simulation of nano-pore formation in EB-PVD thermal barrier coatings. Surf Coat Technol 2004, 187: 399-407.
[394]
Matsumoto M, Kato T, Yamaguchi N, et al. Thermal conductivity and thermal cycle life of La2O3 and HfO2 doped ZrO2-Y2O3 coatings produced by EB-PVD. Surf Coat Technol 2009, 203: 2835-2840.
[395]
Singh J, Wolfe DE, Miller RA, et al. Tailored microstructure of zirconia and hafnia-based thermal barrier coatings with low thermal conductivity and high hemispherical reflectance by EB-PVD. J Mater Sci 2004, 39: 1975-1985.
[396]
Yanar NM, Helminiak M, Meier GH, et al. Comparison of the failures during cyclic oxidation of yttria-stabilized (7 to 8 weight percent) zirconia thermal barrier coatings fabricated via electron beam physical vapor deposition and air plasma spray. Metall Mater Trans A 2011, 42: 905-921.
[397]
Shen ZY, He LM, Xu ZH, et al. LZC/YSZ double layer coatings: EB-PVD, microstructure and thermal cycling life. Surf Coat Technol 2019, 367: 86-90.
[398]
Von Niessen K, Gindrat M. Plasma spray-PVD: A new thermal spray process to deposit out of the vapor phase. J Therm Spray Technol 2011, 20: 736-743.
[399]
Liu MJ, Yang GJ. Condensation behavior of gaseous phase during transported in the near-substrate boundary layer of plasma spray-physical vapor deposition. J Mater Sci Technol 2021, 67: 127-134.
[400]
Dong L, Liu MJ, Zhang XF, et al. Pressure infiltration of molten aluminum for densification of environmental barrier coatings. J Adv Ceram 2022, 11: 145-157.
[401]
Gao LH, Wei LL, Guo HB, et al. Deposition mechanisms of yttria-stabilized zirconia coatings during plasma spray physical vapor deposition. Ceram Int 2016, 42: 5530-5536.
[402]
Goral M, Kotowski S, Sieniawski J. The technology of plasma spray physical vapour deposition. High Temp Mater Process 2013, 32: 33-39.
[403]
Hospach A, Mauer G, Vaßen R, et al. Columnar-structured thermal barrier coatings (TBCs) by thin film low-pressure plasma spraying (LPPS-TF). J Therm Spray Technol 2011, 20: 116-120.
[404]
Von Niessen K, Eschendorff G, Gindrat M, et al. Advanced TBC systems by vapor deposition using LPPS thin film. In: Proceedings of the ASME Turbo Expo: Power for Land, Sea, and Air. Berlin, Germany, 2008: 263-268.
[405]
Góral M, Kotowski S, Drajewicz M, et al. The PS-PVD method—Formation of columnar TBCs on CMSX-4 superalloy. J Achiev Mater Manu Eng 2012, 55: 907-911.
[406]
Mauer G, Hospach A, Zotov N, et al. Process conditions and microstructures of ceramic coatings by gas phase deposition based on plasma spraying. J Therm Spray Technol 2013, 22: 83-89.
[407]
Zhang XF, Zhou KS, Liu M, et al. Toughness and elasticity behaviors in nano-structured 7 wt.% Y2O3-stabilized ZrO2 coating. Surf Coat Technol 2015, 276: 316-319.
[408]
Mauer G. Plasma characteristics and plasma-feedstock interaction under PS-PVD process conditions. Plasma Chem Plasma Process 2014, 34: 1171-1186.
[409]
Anwaar A, Wei LL, Guo HB, et al. Plasma-powder feedstock interaction during plasma spray-physical vapor deposition. J Therm Spray Technol 2017, 26: 292-301.
[410]
Liu MJ, Zhang M, Zhang Q, et al. Evaporation of droplets in plasma spray-physical vapor deposition based on energy compensation between self-cooling and plasma heat transfer. J Therm Spray Technol 2017, 26: 1641-1650.
[411]
Liu MJ, Zhang M, Zhang Q, et al. Gaseous material capacity of open plasma jet in plasma spray-physical vapor deposition process. Appl Surf Sci 2018, 428: 877-884.
[412]
Chen Q-Y, Peng X-Z, Yang G-J, et al. Characterization of plasma jet in plasma spray-physical vapor deposition of YSZ using a < 80 kW shrouded torch based on optical emission spectroscopy. J Therm Spray Technol 2015, 24: 1038-1045.
DOI
[413]
Liu MJ, Zhang KJ, Zhang Q, et al. Thermodynamic conditions for cluster formation in supersaturated boundary layer during plasma spray-physical vapor deposition. Appl Surf Sci 2019, 471: 950-959.
[414]
Liu MJ, Zhang M, Zhang XF, et al. Transport and deposition behaviors of vapor coating materials in plasma spray-physical vapor deposition. Appl Surf Sci 2019, 486: 80-92.
[415]
Gell M. Application opportunities for nanostructured materials and coatings. Mater Sci Eng A 1995, 204: 246-251.
[416]
Siegel RW. Nanostructured materials—Mind over matter. Nanostruct Mater 1993, 3: 1-18.
[417]
Lu YL, Liaw PK. The mechanical properties of nanostructured materials. J Min Met Mater Soc 2001, 53: 31-35.
[418]
Chen H, Ding CX. Nanostructured zirconia coating prepared by atmospheric plasma spraying. Surf Coat Technol 2002, 150: 31-36.
[419]
Zeng Y, Lee SW, Gao L, et al. Atmospheric plasma sprayed coatings of nanostructured zirconia. J Eur Ceram Soc 2002, 22: 347-351.
[420]
Wang N, Zhou CG, Gong SK, et al. Heat treatment of nanostructured thermal barrier coating. Ceram Int 2007, 33: 1075-1081.
[421]
Lima RS, Marple BR. Thermal spray coatings engineered from nanostructured ceramic agglomerated powders for structural, thermal barrier and biomedical applications: A review. J Therm Spray Technol 2007, 16: 40-63.
[422]
Yang GJ, Li CX, Hao S, et al. Critical bonding temperature for the splat bonding formation during plasma spraying of ceramic materials. Surf Coat Technol 2013, 235: 841-847.
[423]
McPherson R. A review of microstructure and properties of plasma sprayed ceramic coatings. Surf Coat Technol 1989, 39-40: 173-181.
[424]
Lima RS, Kucuk A, Berndt CC. Bimodal distribution of mechanical properties on plasma sprayed nanostructured partially stabilized zirconia. Mater Sci Eng A 2002, 327: 224-232.
[425]
Lima RS, Kucuk A, Berndt CC. Integrity of nanostructured partially stabilized zirconia after plasma spray processing. Mater Sci Eng A 2001, 313: 75-82.
[426]
Wu J, Guo HB, Zhou L, et al. Microstructure and thermal properties of plasma sprayed thermal barrier coatings from nanostructured YSZ. J Therm Spray Technol 2010, 19: 1186-1194.
Journal of Advanced Ceramics
Pages 985-1068
Cite this article:
WEI Z-Y, MENG G-H, CHEN L, et al. Progress in ceramic materials and structure design toward advanced thermal barrier coatings. Journal of Advanced Ceramics, 2022, 11(7): 985-1068. https://doi.org/10.1007/s40145-022-0581-7

2753

Views

611

Downloads

168

Crossref

141

Web of Science

117

Scopus

11

CSCD

Received: 25 October 2021
Revised: 24 January 2022
Accepted: 01 February 2022
Published: 02 July 2022
© The Author(s) 2022.

Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made.

The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.

To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.

Return