During the last decade a number of ceramic materials, mostly oxides have been suggested as new thermal barrier coating (TBC) materials. These new compositions have to compete with the state-of-the-art TBC material yttria stabilized zirconia (YSZ) which turns out to be difficult due to its unique properties. On the other hand YSZ has certain shortcomings especially its limited temperature capability above 1200 °C which necessitate its substitution in advanced gas turbines. In the paper an overview is tried on the different new materials covering especially doped zirconia, pyrochlores, perovskites, and aluminates. Literature results and also results from our own investigations will be presented and compared to the requirements. Finally, the double layer concept, a method to overcome the limited toughness of new TBC materials, will be discussed.

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In an effort to improve the performance of heat engines at high temperatures, advanced surface coatings have been developed from complex perovskites. Materials of Ba/4 )O 3 composition were synthesized and applied as ceramic topcoats of thermal barrier coating (TBC) systems by atmospheric plasma spraying (APS) in single layer and in double-layer combination with conventional yttria stabilized zirconia (YSZ). Microstructural and phase analyses reveal that plasma spraying of complex perovskites is accompanied with the formation of vertical crack networks and secondary oxide phases which influence the failure mechanism of the TBCs. The low value of fracture toughness for the complex perovskites and the thermally grown oxide at the topcoat-bondcoat interface of the TBCs are, however, the major factors which lead to the coating failure on thermal cycling at about 1250°C.

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Advanced ceramic materials of perovskite structure have been developed for potential application in thermal barrier coating systems, in an effort to improve the properties of the pre-existing ones like yttriastabilized zirconia. Yb 2 O 3 and Gd 2 O 3 doped strontium zirconate (SrZrO 3 ) and barium magnesium tantalate (Ba(Mg 1/3 Ta 2/3 )O 3 ) of the ABO 3 and complex A(B 0 1/3 B 00 2/3 )O 3 systems, respectively, have been synthesized using ball milling prior to solid state sintering. Thermal and mechanical investigations show desirable properties for high-temperature coating applications. On atmospheric plasma spraying, the newly developed thermal barrier coatings reveal promising thermal cycle lifetime up to 1350°C.

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