Research progress on application of new thermal barrier coatings in advanced aero-engines

The operating temperatures of hot-section components in advanced aero-engines continue to increase, accompanied by increasingly severe service conditions. Conventional thermal barrier coatings（TBCs）can no longer meet these demanding requirements, necessitating the development of new TBCs with higher temperature resistance and superior overall performance. This paper systematically analyzes the application requirements for new thermal barrier coating materials in advanced aero-engines, focusing on material composition, fabrication processes and microstructure. It elaborates on recent research progress in three types of novel TBCs: rare-earth-doped ZrO₂ coatings applied via atmospheric plasma spraying（APS）, rare-earth zirconate coatings produced by electron beam physical vapor deposition（EB-PVD）, and high-entropy ceramic coatings fabricated through plasma spray-physical vapor deposition （PS-PVD）. Compared to traditional double-layer structured yttria-stabilized zirconia（YSZ） TBCs, these new coating systems—based on rare-earth-doped ZrO₂, rare-earth zirconates, or high-entropy ceramics—exhibit lower thermal conductivity, enhanced thermal shock resistance, and superior resistance to calcium-magnesium-alumino-silicate （CMAS） corrosion. Through in-depth integration with processes such as APS, EB-PVD and PS-PVD, the performance of these coatings has been significantly improved, making them suitable for application in critical hot-section components like floating wall tiles and turbine blades. As breakthroughs continue to emerge in new materials, structures and processes, these advanced thermal barrier coatings are poised to provide crucial support for next-generation aero-engines, enabling them to surpass current temperature limits and achieve greater efficiency and reliability.