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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.

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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.

Keywords

thermal barrier coatings (TBCs)ceramic materialdegradation and failurestructure designlong lifetime

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Journal of Advanced Ceramics
Volume 11 Issue 7,
July 2022
Pages 985-1068
DOI: 10.1007/s40145-022-0581-7

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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

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

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