▪ Abstract  The emphasis in this short review is to describe the materials issues involved in the development of present thermal barrier coatings and the advances necessary for the next generation, higher temperature capability coatings.

Thermal barrier coatings (TBCs) are increasingly susceptible to degradation by molten calcium-magnesium alumino silicate (CMAS) deposits in advanced engines that operate at higher temperatures and in environments laden with siliceous debris. This paper investigates the thermochemical aspects of the degradation phenomena using a model CMAS composition and ZrO 2 -7.6%YO 1.5 (7YSZ) grown by vapor deposition on alumina substrates. The changes in microstructure and chemistry are characterized after isothermal treatments of 4 h at 12001-14001C. It is found that CMAS rapidly penetrates the open structure of the coating as soon as melting occurs, whereupon the original 7YSZ dissolves in the CMAS and reprecipitates with a different morphology and composition that depends on the local melt chemistry. The attack is minimal in the bulk of the coating but severe near the surface and the interface with the substrate, which is also partially dissolved by the melt. The phase evolution is discussed in terms of available thermodynamic information.

Molten deposits based on calcium-magnesium alumino-silicates (CMAS), originating from siliceous debris ingested with the intake air, represent a fundamental threat to progress in gas turbine technology by limiting the operating surface temperature of coated components. The thermomechanical and thermochemical aspects of the CMAS interactions with thermalbarrier coatings, as well as the current status of mitigating strategies, are discussed in this article. Key challenges and research needs for developing adequate solutions are highlighted.

Modern gas turbines rely on ceramic coatings to protect structural components along the hot gas path. These coatings are susceptible to accelerated degradation caused by silicate deposits formed when ingested environmental debris (dust, sand, ash) adheres to the coatings. This article reviews the current understanding of the deposit-induced failure mechanisms for zirconia-based thermal barrier coatings and silicate environmental barrier coatings. Details of the debris melting and crystallization behavior, the nature of the chemical reactions occurring between the deposits and coatings, and the implications for the thermocyclic durability of the coatings are described. Given the challenges posed in understanding how prospective coating materials and architectures will respond to a broad range of deposit compositions, it is proposed to develop an integrated framework linking thermochemical and thermomechanical models to predict coating durability. Initial progress toward developing this framework, and the requisite research needs, are discussed.

The thermochemical interaction between a Gd2Zr2O7 thermal barrier coating synthesized by electron‐beam physical vapor deposition and a model 33CaO–9MgO–13AlO3/2–45SiO2 (CMAS) melt with a melting point of ∼1240°C was investigated. A dense, fine‐grained, ∼6‐μm thick reaction layer formed after 4 h of isothermal exposure to 1300°C. It consisted primarily of an apatite phase based on Gd8Ca2(SiO4)6O2 and fluorite ZrO2 with Gd and Ca in a solid solution. Remarkably, melt infiltration into the intercolumnar gaps was largely suppressed, with penetration rarely exceeding ∼30 μm below the original surface. The microstructural evidence suggests a mechanism in which CMAS infiltration is arrested by rapid filling of the gaps with crystalline reaction products, followed by slow attack of the column tips.

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Continuous fiber ceramic composites (CFCCs) based on oxides are of interest for high-temperature applications owing to their inherent oxidative stability. An enabling element is a matrix with an optimum combination of toughness and strength, which may be achieved by incorporating a controlled amount of fine, well-distributed porosity. Implementation of this concept by vacuum infiltration of aqueous mullite-alumina slurries into two-dimensional woven preforms of alumina fibers has been investigated. Evaluation of these materials shows stress-strain characteristics similar to other CFCCs, especially carbon-matrix composites. Moreover, promising notch and creep properties have been found. Microstructural and processing issues relevant to the attainment of these behaviors are discussed.