Abstract
Abstract The science and technology of thermal barrier coatings has advanced considerably since reports of the first test on turbine blades in a research engine in 1976. Today thermal barrier coatings are flying in revenue service in a low risk location within the turbine section of certain gas turbine engines. The state-of-the-art coating system for gas turbine applications is currently a plasma-sprayed ZrO 2 -(6%–8%) Y 2 O 3 ceramic layer over an MCrAlY (M ≡ Ni, Co or NiCo) bond coat layer plasma sprayed at low pressure. Although the potential for meeting current and short-term goals is high, longer-range goals may not be attainable with current coating concepts. These longer-range goals will involve high risk designs where coating loss could lead directly to component loss. Several steps must be taken to help meet these goals. Improved understanding of coating failure mechanisms is required. Models are needed to predict lifetimes. Process automation and quality control procedures must be instituted. Finally, new concepts in plasma-sprayed coatings must be developed and alternatives to the plasma- spraying process may be required. The current status of thermal barrier coatings and prospects for future progress in the above areas are summarized.
Published Version
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