Durability Of Thermal Barrier Coatings Research Articles

Debonding defect imaging of thermal barrier coating with grating laser acoustic spectroscopy

Thermal barrier coatings (TBCs) are crucial for protecting high-temperature components in gas turbines and aeroengines. However, conventional non-destructive testing (NDT) methods, such as infrared thermography, face challenges in precisely detecting and quantifying debonding defects due to limitations in imaging contrast and sensitivity to surface states. In this work, a novel scheme for imaging debonding defects in TBCs using grating laser acoustic spectroscopy is proposed. The scheme, validated by numerical simulations and experimental results, is the first to introduce the mode conversion mechanism of Rayleigh and Lamb waves in the field of TBCs, achieving noncontact photoacoustic imaging of debonding defects for the first report. The all-optical laser ultrasonics system generates velocity maps with enhanced contrast and immunity to surface states, outperforming infrared thermography. Threshold segmentation precisely outlines defect contours, enabling precise quantification of defect size with an error below 5%. This work demonstrates a noncontact, precise, high-contrast imaging and surface-state-immune technique for evaluating the integrity and durability of TBCs, with potential applications in engineering.

Extending interfacial toughness and thermal cycling lifetime of thermal barrier coatings via interfacial 3D pattern

AbstractWeak interface bonding is a critical factor that compromises the long‐term durability of the thermal barrier coatings. To mitigate this, we introduce an innovative interface‐strengthening approach by integrating four types of 3D patterns at the top coat/bond coat interface using the laser cladding technique. Tensile tests demonstrate a significant enhancement in interfacial bonding strength, increasing by over 139.2% from 21.6 ± 1.7 MPa for conventional thermal barrier coatings without patterns to 51.67 MPa for the patterned coatings. Moreover, the thermal cycling lifetime has been extended by 41%, from 1026 ± 25 cycles for the conventional coating to 1936 ± 164 cycles for the patterned coating. This enhancement in interfacial toughness and thermal cycling lifetime is primarily because of the blocking and deflection effects of 3D patterns on interfacial crack propagation. Besides, the geometric parameters of the patterns play a crucial role in determining the failure behavior of the thermal barrier coatings. This strategy presents a practical solution for the development of durable thermal barrier coatings and provides the valuable insights for the optimization of other heterogeneous interfaces.

CMAS resistance characteristics of Gd2(Hf0.7Ce0.3)2O7 thermal barrier material at 1300 °C and 1400 °C

The corrosion resistance to calcium‑magnesium‑aluminum-silicate (CMAS) is a key property affecting the long-term durability of thermal barrier coatings (TBCs). Meanwhile, rare-earth hafnates are considered promising TBC candidates due to their low thermal conductivity and suitable thermal expansion coefficients. Thus, this study explores the CMAS corrosion resistance of Gd2(Hf0.7Ce0.3)2O7 (GH7C3) ceramic material under different conditions and compares it with the binary system Gd2Hf2O7 (GH) ceramic material. The findings indicate that GH7C3 can react chemically with CMAS and rapidly form a dense apatite crystalline layer at the interface between GH7C3 ceramic and CMAS, providing excellent CMAS resistance. Furthermore, the composition of the remaining CMAS melt Furthermore, the composition of the remaining CMAS melt undergoes compositional changes upon interaction, ultimately forming spinel in Mg and Al-enriched regions. In the meantime, CeO2 can promote the rapid formation of apatite crystals, significantly enhancing the CMAS resistance of GH7C3 to CMAS at high temperatures compared to GH.

Thick Columnar-Structured Thermal Barrier Coatings Using the Suspension Plasma Spray Process

Higher operating temperatures for gas turbine engines require highly durable thermal barrier coatings (TBCs) with improved insulation properties. A suspension plasma spray process (SPS) had been developed for the deposition of columnar-structured TBCs. SPS columnar TBCs are normally achieved at a short standoff distance (50.0 mm–75.0 mm), which is not practical when coating complex-shaped engine hardware since the plasma torch may collide with the components being sprayed. Therefore, it is critical to develop SPS columnar TBCs at longer standoff distances. In this work, a commercially available pressure-based suspension delivery system was used to deliver the suspension to the plasma jet, and a high-enthalpy TriplexPro-210 plasma torch was used for the SPS coating deposition. Suspension injection pressure was optimized to maximize the number of droplets injected into the hot plasma core and achieving the best particle-melting states and deposition efficiency. The highest deposition efficiency of 51% was achieved at 0.34 MPa injection pressure with a suspension flow rate of 31.0 g/min. With the optimized process parameters, 1000 μm thick columnar-structured SPS 8 wt% Y2O3-stabilized ZrO2 (8YSZ) TBCs were successfully developed at a standoff distance of 100.0 mm. The SPS TBCs have a columnar width between 100 μm and 300 μm with a porosity of ~22%. Furnace cycling tests at 1125 °C showed the SPS columnar TBCs had an average life of 1012 cycles, which is ~2.5 times that of reference air-plasma-sprayed dense vertically cracked TBCs with the same coating thickness. The superior durability of the SPS columnar TBCs can be attributed to the high-strain-tolerant microstructure. SEM cross-section characterization indicated the failure of the SPS TBCs occurred at the ceramic top coat and thermally grown oxide (TGO) interface.

Thermal shock behavior of novel (Yb0.1Gd0.9)2Zr2O7 thermal barrier coatings with a Cr modified (Ni, Pt)Al bond coat

The durability of thermal barrier coatings (TBCs) is significantly influenced both by the ceramic top coat and the bond coat. In this study, novel YbGdZrO ceramic coats were deposited on the surfaces of three types of Cr-modified (Ni, Pt)Al bond coats via electron beam physical vapor deposition (EB-PVD) technique. These Cr-modified (Ni, Pt)Al bond coats were fabricated by magnetic sputtering Cr onto the (Ni, Pt)Al bond coats with varying sputtering times of 30, 60, and 90 min. The results indicates that the thickness of the Cr-modified layer increases with the extension of sputtering time. A short deposition time of 30 min is adequate for achieving an appropriate Cr content in the (Ni, Pt)Al bond coats, which ensures selective oxidation of Al element within the bond coat and further enhances the metallurgical interfacial bonding strength with the ceramic coat by adapting to the concentration gradient diffusion. However, as the sputtering time is extended to 60 and 90 min, α-Cr begins to form in the Cr-modified (Ni, Pt)Al bond coats, which negatively affects the oxidation resistance of the bond coat. Consequently, the thermal shock life of the TBCs samples is significantly reduced with increasing sputtering time. The longest thermal shock lifetime is obtained on the bond coat with Cr plating time of 30 min owing to a differing thermally grown oxide formation and failure mechanism.

A Comprehensive Understanding of Thermal Barrier Coatings (TBCs): Applications, Materials, Coating Design and Failure Mechanisms

This review offers a comprehensive analysis of thermal barrier coatings (TBCs) applied to metallic materials. By reviewing the recent literature, this paper reports on a collection of technical information, involving the structure and role of TBCs, various materials and coating processes, as well as the mechanisms involved in the durability and failure of TBCs. Although TBCs have been successfully utilized in advanced applications for nearly five decades, they continue to be a subject of keen interest and ongoing study in the world of materials science, with overviews of the field’s evolution remaining ever relevant. Thus, this paper outlines the current requirements of the main application areas of TBCs (aerospace, power generation and the automotive and naval industries) and the properties and resistance to thermal, mechanical and chemical stress of the different types of materials used, such as zirconates, niobates, tantalates or mullite. Additionally, recent approaches in the literature, such as high-entropy coatings and multilayer coatings, are presented and discussed. By analyzing the failure processes of TBCs, issues related to delamination, spallation, erosion and oxidation are revealed. Integrating TBCs with the latest generations of superalloys, as well as examining heat transfer mechanisms, could represent key areas for in-depth study.

Unveiling thermal stresses in RETaO4 (RE = Nd, Sm, Eu, Gd, Tb, Dy, Ho and Er) by first-principles calculations and finite element simulations

Thermal stress (σ) plays a critical role in regulating the stability and durability of thermal barrier coatings (TBCs) during service. However, its measurements are limited due to technical challenges. Here, thermal stresses in RETaO4 (RE = Nd, Sm, Eu, Gd, Tb, Dy, Ho, and Er) TBCs have been evaluated by a cross-scale model, integrating first-principles calculations and finite element simulations (FEM). The isobaric heat capacity, thermal expansion coefficients, density, Young's modulus, and Poisson's ratio of RETaO4 as a function of temperature have been determined by the quasi-harmonic approach (QHA) and the quasi-static approach (QSA). Taking these properties as the input data of FEM, the σ of TBCs with RETaO4 as ceramic coatings is estimated. It indicates that the maximum tensile stress exists at the ceramic and thermal-grown oxide coating interface. Notably, TBCs_NdTaO4 exhibits the highest tensile stress, reaching up to 2093 MPa, while TBCs_GdTaO4 has the lowest value at 1880 MPa. Furthermore, the key factors affecting σ are estimated using interpretable machine learning based on the decision tree algorithm. The RETaO4 with small Poisson's ratio, strong electronegativity, small heat capacity, and thermal expansion coefficients is helpful to achieving low σ in TBCs. GdTaO4, YTaO4 and (Ho0.5Er0.5)TaO4 emerge as more favorable options as ceramic layer due to their lower σ in TBCs. This present cross-scale model provides a successful tool for predicting σ and the reverse design of TBCs materials based on low σ in TBCs.

High temperature hardness and thermal analysis of CoNiCrAlY alloys used as bond coats for thermal barrier coatings

CoNiCrAlY alloys, commonly used as the bond coat of thermal barrier coatings (TBCs), are often exposed to high temperatures of about 1000 °C, the evolution of mechanical and thermal properties is critical to the reliability and durability of TBCs. In this paper, the hardness and thermal properties (weight change and heat flow) of CoNiCrAlY alloys at temperatures within 1000 °C were evaluated by indentation and TGA-DSC thermal analysis. It was found that hardness and thermal properties change gradually within 600 °C but change sharply above 600 °C, exhibiting an approximately synchronized evolution. An illustrative explanation was given for the correlation in terms of the Boltzmann energy distribution theory of microscopic particles. Based on these findings, an idea of inter-calibration between the two evolutions was proposed.

The Oxidation Behaviors of NiCoCrAlY Coatings After Pre-Oxidation Treatment During High-Temperature Oxidation at 800 ℃ and 900 ℃

Thermal barrier coatings (TBCs) are essential for protecting the high-temperature components in gas turbines. However, the durability of TBCs is limited, and new technologies to improve their lifetime are necessary. This study focuses on the pre-oxidation treatment of the NiCoCrAlY bond coat in TBCs to reduce the growth rate of the thermally grown oxide (TGO) and improve the TBC lifetime. The mechanism of the TGO growth rate reduction by the pre-oxidation treatment of NiCoCrAlY was investigated. Oxidation behaviors of the surface of NiCoCrAlY coating samples with or without pre-oxidation treatment were evaluated in air at 800 °C and 900 °C. In-situ X-ray diffraction (XRD) measurements and isothermal oxidation tests were performed. The obtained results revealed that the growth rate of TGO is significantly suppressed by α-Al2O3 layer formed by the pre-oxidation treatment. The generation of γ-Al2O3 and θ-Al2O3, which are typically formed below 900 °C, was significantly reduced by pre-oxidation. It is suggested that this reduction suppresses of the TGO growth.

Failure behaviors of EB-PVD thermal barrier coatings under isothermal oxidation and thermal cycling conditions

The thermal growth oxide (TGO) layer formed by oxidation of the bond coat (BC) layer is an important factor affecting the durability of thermal barrier coatings (TBCs). In this study, a series of isothermal oxidation and thermal cycling experiments were performed on samples containing TBCs at different temperatures. The initiation, propagation and connection process of cracks in the cross-section of the samples were studied, and the oxidation failure mechanism of the samples was analyzed. The results demonstrate that the diffusion of the Al element in NiCoCrAlYHf coating to the top coat (TC) layer promotes the formation and rapid thickening of TGO at TC/BC interface. With the consumption of Al, two sublayers of mixed oxide layer and Al2O3 layer are gradually formed in the TGO layer. The TC/TGO interface is the main initiation location of interface crack. In addition, the types and initiation locations of cracks caused by isothermal oxidation are different from those caused by thermal cycling. Under isothermal oxidation, the TC layer near the TC/TGO interface and the TC/TGO interface are prone to induce horizontal cracks, which finally lead to the delamination and spalling of TBCs. Under the thermal cycling, vertical cracks occur in the TC layer, extend towards the TC/TGO interface, and merge with the interface cracks, eventually resulting in the delamination failure of the TBCs.

SEM-Guided Finite Element Simulation of Thermal Stresses in Multilayered Suspension Plasma-Sprayed TBCs

This study presents novel insights into thermal stress development and crack propagation mechanisms in single- and multilayered suspension plasma-sprayed (SPS) coatings of gadolinium zirconate (GZ) and yttria-stabilized zirconia (YSZ), thermally treated at 1150 °C. By combining image processing with finite element simulation, we pinpointed sites of high-stress concentration in the coatings, leading to specific cracking patterns. Our findings reveal a dynamic shift in the location of stress concentration from intercolumnar gaps to pores near the top coat/thermally grown oxide (TGO) interface with TGO thickening at elevated temperatures, promoting horizontal crack development across the ceramic layers. Significantly, the interface between the ceramic layer and TGO was found to be a critical area, experiencing the highest levels of both normal and shear stresses. These stresses influence failure modes: in double-layer SPS structures, relatively higher shear stresses can result in mode II failure, while in single-layer systems, the predominant normal stresses tend to cause mode I failure. Understanding stress behavior and failure mechanisms is essential for enhancing the durability of thermal barrier coatings (TBCs) in high-temperature applications. Therefore, by controlling the interfaces’ roughness along with improving interfacial toughness, the initiation and propagation of cracks can be delayed along these interfaces. Moreover, efforts to optimize the level of microstructural discontinuities, such as intercolumnar gaps and pores, within the creaming layer and close to the TGO interface should be undertaken to reduce crack formation in the TBC system.

Integrating APS TBCs with a built-in Al2O3 protection network for superior CMAS resistance

Calcium–magnesium–alumina–silicate (CMAS) attack poses a great threat to the durability of thermal barrier coatings (TBCs). We introduce a novel Al2O3-modified TBC architecture to counter this threat. The architecture integrates an Al2O3 protection network into the microstructure of an atmospheric plasma sprayed (APS) TBC by drip coating method, which modifies the vulnerable infiltration pathway of CMAS melt and promotes the self-crystallization of CMAS at the infiltration front. Moreover, during sintering, the built-in Al2O3 can inhibit inter-splat crack healing. This innovative TBC design achieves robust CMAS resistance and strain tolerance, while also offering advantages during sintering.

CMAS corrosion resistance of YSZ thermal barrier coatings enhanced by Pt–Al films

Corrosion of calcium magnesium aluminum silicate (CMAS) severely affects the durability of thermal barrier coatings (TBCs). In this study, 8 wt% Y2O3 partially stabilized ZrO2 (8YSZ) coatings were prepared using atmospheric plasma spraying (APS) technique, and a Pt–Al film was magnetron-sputtered onto the surface of the YSZ coating (Pt–Al-YSZ) to enhance its resistance against CMAS. The results indicated that the Pt–Al-YSZ coating displayed superior non-wetting performance against CMAS, as well as stronger resistance to CMAS corrosion. The results evidenced by Raman spectra and X-ray diffraction showed that phase transformation was smaller and corrosion depth was lower after CMAS corrosion at 1250 °C for 2 h. The thermal cycling test was also performed. The result demonstrated that the Pt–Al coating did not have a negative impact on the thermal cycling life of the YSZ TBCs. However, platinum tended to soften at high temperatures and became easily penetrated by molten CMAS. Therefore, it is necessary to further improve the strength of platinum layer to fully utilize its protective effect against CMAS attack.

Peridynamics–FEM Coupling for Interfacial Delamination Effected by Vertical Crack Density in Thermal Barrier Coatings

A coupling model of peridynamics and finite element method is proposed to study the interfacial delamination influenced by vertical crack density in thermal barrier coating (TBC) systems. Specifically, the progressive failure progress under static and fatigue loads in TBCs, including vertical cracks propagation, the evolution of vertical cracks to interfacial cracks, and interfacial delamination, is simulated by the proposed model. The difference between static failure mechanism and fatigue failure mechanism of TBCs is numerically elucidated. The simulated fracture morphology is in good agreement with the experiential observation. In both static and fatigue loads, a higher vertical crack density is found to correspond to a shorter delamination length, and there is no interfacial delamination when the vertical crack density is high enough. The results provide important insight of vertical crack density on interfacial delamination, and the durability of TBCs can be enhanced by ensuring an appropriately high vertical crack density.

Corrosion behaviour of La2Hf2O7 thermal barrier coatings against molten CMAS melts at 1300 and 1500 °C

Thermal barrier coatings (TBCs) are susceptible to accelerated degradation caused by molten calcium-magnesium-alumino-silicate (CMAS), which exhibits a significant challenge to design and develop durable TBCs. Rare-earth hafnates are regarded as promising TBCs candidates. In this study, the corrosion behaviour of plasma-sprayed La2Hf2O7 coating at 1300 and 1500 °C was investigated and compared with the traditional YSZ coating. The study indicated that the La2Hf2O7 exhibited better corrosion resistance than the YSZ. During the corrosion process, La2Hf2O7 coating dissolved into CMAS melts and reprecipitated m-HfO2 and apatite which effectively mitigate the corrosion, while the YSZ coating only produced ZrO2 with a transition from tetragonal to monoclinic phase. The recession depth of the coatings increases noticeably when the reaction temperature raised from 1300 to 1500 °C. The YSZ coating failed at 1500 °C, while the La2Hf2O7 coating still remained intact. This study may provide a theoretical basis for selecting and design of rare-earth hafnates TBCs with excellent corrosion resistance.

Recent Development in Advance Ceramic Materials and Understanding the Mechanisms of Thermal Barrier Coatings Degradation

AbstractMetallic alloys' behavior at high temperatures, especially their response to corrosion and formation of protective surface layers, has long been a focus of scientific inquiry. Although certain alloy compositions require an initiation period before hot corrosion advances to the propagation stage, no combination of alloys can be considered impervious to hot corrosion indefinitely. The capacity of nickel-based materials to tolerate extreme circumstances such high temperatures, acidity, corrosion, and scratching is highly valued. However, they are unable to satisfy the strict demands of today's high-temperature applications. The durability of thermal barrier coatings (TBCs), which are prone to oxidation, rust, and degradation from sulphates and foreign object damage, has been the subject of recent study. For sophisticated ceramic materials exposed to high temperatures, hot rust degradation poses a considerable challenge. The main objective of this study is to investigate the effects of severe degradation on several advanced ceramic material types and their level of advancement. The purpose of the inquiry is to comprehend the deteriorating processes at the long term working condition, including the function of oxidation and liquid salts. Additionally, we investigate the effects of temperature, environment, and contact duration on the heated weathering behavior of earthenware. Finally, we discuss strategies for mitigating hot corrosion degradation in ceramics, such as protective coatings like new design of TBCs, doping, and composition optimization. This paper aims to offer a thorough understanding of the hot corrosion behavior of ceramics, which is crucial for developing durable materials suitable for high-temperature applications. Additionally, it explores the fabrication of protective coatings and addresses the challenges faced in this regard. The insights gained from this research can contribute to the advancement of resilient ceramic fabrics and the development of effective protective coatings.

Service life assessment of yttria stabilized zirconia (YSZ) based thermal barrier coating through wear behaviour

Countless research has suggested Yttria-stabilized Zirconia (YSZ) to be a top candidate for being implemented as thermal barrier coatings (TBC). However, when exposed to prolonged service, temperature and stress variations succeed in initiating a catastrophic phase transformation from tetragonal to monoclinic structure in Zirconia. Hence, the estimation of endurance for YSZ-based TBC is necessary to minimize failure in such situations. The main purpose of this research was to determine the relationship between tribological investigations and the estimated lifespan of YSZ coatings accurately. The study used various methods such as wear resistance testing, optical profilometry, specific wear rate, and coefficient of friction to estimate the maximum durability of TBCs. The research also provided insights into the composition and microstructure of the TBC system and found the optimized concentration of Yttrium doping to be 3.5 wt %. The study discovered that erosion was the main cause of roughness depreciation from SN to S1000. The estimation of the service life was primarily made based on optical profilometry, specific wear rate (SWR), coefficient of friction (COF) and wear resistance values which were further supported by the results of chemical characterization of the samples through electron dispersive spectroscopy (EDS), wavelength dispersive spectroscopy (WDS) and X-Ray Diffraction (XRD) analysis. The results were reliable and accurate and suggested future areas of investigation, such as 3D profilometry for surface roughness and thermal conductivity evaluation using laser-assisted infrared thermometers.

Novel Thermal Barrier Coatings with Phase Composite Structures for Extreme Environment Applications: Concept, Process, Evaluation and Performance

In this paper, a novel concept in the field of phase composite ceramics has been proposed and applied for creating the topcoats of durable thermal barrier coatings (TBCs), which is one of the most critical technologies for advanced high-efficiency gas turbine engines in extreme environments. The phase composite ceramic TBCs were designed to demonstrate superior and comprehensive performance-related merits, benefits, and advantages over conventional single-phase TBCs with a topcoat of 8YSZ or Gd2Zr2O7, including thermal phase stability, thermal shock durability, low thermal conductivity, and solid particle erosion resistance. In this paper, we review and summarize the development work conducted so far related to the phase composite ceramic concept, coatings processing, and experimental investigation into TBC behaviors at elevated temperatures (typically, ≥1250 °C) using different evaluation and characterization methods, including isothermal sintering, a burner rig test, a solid particle-impinging erosion test, and a CMAS corrosion test. Two-phase (t’+c) zirconia-based TBCs demonstrated improved thermal shock and erosion resistance in comparison to conventional single-phase (t’), 8YSZ TBC, and Gd2Zr2O7 TBC, when used separately. Additionally, a triple-phase (t’+c+YAG) TBC sample demonstrated superior CMAS resistance. The TBC’s damage modes and failure mechanisms for thermal phase stability, thermal cycling resistance, solid particle erosion behavior, and CMAS infiltration are also characterized and discussed in detail, in terms of microstructural characterization and performance evaluation.

Study of toughening behavior of SiC whiskers on 8YSZ thermal barrier coatings

The embrittlement of thermal barrier coatings (TBCs) in a high-temperature service environment inhibits the ability of the top-coat to resist crack initiation and propagation, in which the cracks are generated by erosion or wear of particles, limiting the service durability of TBCs. This study was based on the preparation of SiC whiskers (SiCw) / Y2O3 partially stabilized ZrO2 (YSZ) integrated composite powder, and the SiCw/YSZ composite TBCs was prepared through the atmospheric plasma spraying (APS) to improve the toughness of the top-coat. The effects of SiCw on the fracture toughness, tribological properties, erosion resistance and bending strength of the coatings were studied. The results showed that the fracture toughness of the composite coating with a SiCw length-to-diameter ratio (L/D ratio) of 250 was 24.6 % higher than the YSZ coating. Moreover, the composite coating presented excellent performance in wear, erosion, and resistance to crack propagation and spallation. The low amplitude of the Weibull modulus m of hardness distribution of the doped coating proved the stability effect of SiCw on the reinforcement and toughening of the coating.

Evaluation of Thermal Cycle Durability of Thermal Barrier Coating by Laser Speckle Method and AE Method with Continuous Waveform Recording

Evaluation of Thermal Cycle Durability of Thermal Barrier Coating by Laser Speckle Method and AE Method with Continuous Waveform Recording