A review on failure mechanism of thermal barrier coatings and strategies to extend their lifetime

Mehboob, Ghazanfar; Liu, Meijun; Xu, Tong; Hussain, Shahnwaz; Mehboob, Gohar; Tahir, Adnan

doi:10.1016/j.ceramint.2019.12.200

Cited by 136 publications

(45 citation statements)

References 459 publications

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“…In particular, considerable efforts are directed at attempts to implement them for improving the functional characteristics of austenitic stainless steels [11][12][13][14][15][16][17][18][19][20][21][22][23][24][25]. Key challenges for the success of these endeavors are incompatibility of microstructures and properties of the materials at the metal/ceramic interfaces [13,14,, as well as residual stresses in the coatings [13,21,[52][53][54][55], causing low adhesion and their delamination from the substrates. It should be noted that morphology (roughness) and other characteristics of the substrate surface layers also have a significant effect on the obtained results [21,56,57].…”

Section: Introductionmentioning

confidence: 99%

Effect of Preliminary Irradiation of 321 Steel Substrates with High-Intense Pulsed Ion Beams on Scratch Test Results of Subsequently Deposited AlN Coatings

et al. 2021

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The paper presents the effect of irradiation of 321 steel substrates with a high-intense pulsed ion beam (HIPIB) on changes in functional properties of the surface layers and tribological characteristics of AlN coatings subsequently deposited above by the reactive magnetron sputtering method. The morphology of the modified surface layers, their microhardness and free surface energy levels are presented for different HIPIB energy densities. HIPIB irradiation of the substrates caused variations in the results of scratch tests combined with the acoustic emission signal processing. Their analysis has enabled concluding that the crack initiation threshold could be at least doubled for the studied coating/substrate system due to preliminary HIPIB irradiation. Finally, the obtained data were discussed, and future research directions were proposed.

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Section: Introductionmentioning

confidence: 99%

Effect of Preliminary Irradiation of 321 Steel Substrates with High-Intense Pulsed Ion Beams on Scratch Test Results of Subsequently Deposited AlN Coatings

et al. 2021

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“…Key requirements in TBCs that form the basis of performance assessment are listed here. The comparative analysis and discussions in the following sections will be based on these parameters to comprehend the improvements and shortcomings in N tbc and C tbc systems [25][26][27][28][29][30][31][32][33][34][35][36][37][38][39][40][41][42].…”

Section: Tbc Requirementsmentioning

confidence: 99%

“…Tetragonal zirconia in a metastable phase (t'-ZrO 2 ) is considered ideal due to its low intrinsic thermal conductivity (~2.5 W/mK) and high fracture toughness A different processing route, namely nanostructuring of standard TBC materials, has generated tremendous interests in industry and academia recently. Nanostructured thermal barrier coatings (Ntbc) have exhibited superior thermal insulation effect, strain compliance, low thermal conductivity and good thermomechanical properties over conventional TBCs (Ctbc) [17,[35][36][37][38][39][40]. Nanotechnology has been successfully applied to modify the microstructure with porosity control in 7%-8% YSZ TBC.…”

Section: Introductionmentioning

confidence: 99%

Nano-Micro-Structured 6%–8% YSZ Thermal Barrier Coatings: A Comprehensive Review of Comparative Performance Analysis

Amarnath¹,

Moledina²,

Liu³

et al. 2021

Coatings

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Beneficial properties achieved by nanostructuring effects in materials have generated tremendous interests in applications in surface engineering, especially in thermal barrier coatings (TBC). Limitations in conventional TBC processing for gas turbines and aero-propulsion systems have been exposed during past decades when rapid progress was made in nano-structuring coating research and developments. The present work is a comprehensive review of the current state of progress in nanostructured TBC (Ntbc) in reference to its microstructure, damage progression, failure mechanisms and a wide range of properties. The review aims to address the comparative performance analysis between the nanostructured and conventional (microstructured) 6–8 wt.% yttrium stabilized zirconia (YSZ) TBC systems. Oxidation resistance and sintering behavior in two TBCs are considered as the central focus of discussion. A few schematics are used to represent major microstructural features and failure progression. A performance analysis is performed for standard 2-layer, as well as functionally graded multilayer, TBC systems. A comparison of TBC characteristics processed by plasma spray and vapor deposition techniques is also made as reference. Compared to the sea of R&D efforts made for conventional TBC (Ctbc), limited experimental studies on Ntbc offers conflicting data, and prediction modeling and computational research are scarce.

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“…The excellent properties of 8YSZ are attributed to its columnar microstructure with perfect strain tolerance and adhesion, prevention of phase transformation of ZrO 2 by yttrium, and reduction in thermal conductivity by oxygen vacancies and yttrium. However, despite these impressive properties, YSZ coatings exhibit certain disadvantages, such as a limited operating temperature (1200 • C), hot corrosion, and phase transformation (~1200 • C) [12][13][14]. Hence, 8YSZ is less stable above 1200 • C, and its thermal conductivity should be lowered to withstand high temperatures [15].…”

Section: Introductionmentioning

confidence: 99%

Interfacial Structure and Physical Properties of High-Entropy Oxide Coatings Prepared via Atmospheric Plasma Spraying

et al. 2021

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The feasibility of using a high-entropy rare-earth oxide (REO) as a top coating material for thermal barrier coatings was explored using the atmospheric plasma spray technique. The microstructure and Vickers hardness of the coating layer were compared to those of an 8 mol % yttria-stabilized zirconia (8YSZ) top coating material. Macroscopic observations revealed the formation of a well-coated surface with no surface defects or delamination. Scanning electron microscopy images showed the presence of several parallel and vertical microcracks in the REO and 8YSZ coating layers. The origin of these cracks is attributed to differences in the coefficient of thermal expansion, very fast cooling, and process parameters. X-ray diffraction demonstrated the high phase stability and excellent thermal properties of REO due to the absence of phase transformation after plasma spray processing. The measured Vickers hardness of REO was 425 HV, which is lower than that of sintered REO powder and the 8YSZ coating.

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A review on failure mechanism of thermal barrier coatings and strategies to extend their lifetime

Cited by 136 publications

References 459 publications

Effect of Preliminary Irradiation of 321 Steel Substrates with High-Intense Pulsed Ion Beams on Scratch Test Results of Subsequently Deposited AlN Coatings

Effect of Preliminary Irradiation of 321 Steel Substrates with High-Intense Pulsed Ion Beams on Scratch Test Results of Subsequently Deposited AlN Coatings

Nano-Micro-Structured 6%–8% YSZ Thermal Barrier Coatings: A Comprehensive Review of Comparative Performance Analysis

Interfacial Structure and Physical Properties of High-Entropy Oxide Coatings Prepared via Atmospheric Plasma Spraying

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