Multi-Scale Structural Design and Advanced Materials for Thermal Barrier Coatings with High Thermal Insulation: A Review

Song, Jin-Bao; Wang, Lishuang; Yao, Jian-Tao; Dong, Hui

doi:10.3390/coatings13020343

Cited by 8 publications

(6 citation statements)

References 234 publications

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“…As shown in Fig. 14 [108], typical TBCs comprise of a topcoat (TC), a bond coat (BC), a thermally grown oxide (TGO), and a substrate. Thermal insulation and resistance to calcium-magnesium-alumina-silicate (CMAS) corrosion are functions of the TC, whereas bond strengthening, oxidation resistance, and mechanical property transition are functions of the BC.…”

Section: Thermally Sprayed Coatingsmentioning

confidence: 99%

“…In contrast to a columnar design, a compressed structure may delay the entry of the liquid caustic ions, according to Song et al (2020). the presence of sodium sulphate causes an extremely rapid type of oxidation to take place between 1500 °F (816 °C) and 1700 °F (927 °C) (Na 2 SO 4 ) [108]. Sodium sulphate is created as a result of the reaction between sodium, sulphur, and oxygen during combustion.…”

Section: Accelerated Corrosionmentioning

confidence: 99%

“…Fig. 14 Schematic diagram of the deposited coatings: a sprayed machines, b coatings structures, c surface SEM images[108] …”

mentioning

confidence: 99%

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

Iqbal

Moskal

2023

Arch Computat Methods Eng

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Metallic 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.

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Section: Thermally Sprayed Coatingsmentioning

confidence: 99%

Section: Accelerated Corrosionmentioning

confidence: 99%

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

Iqbal

Moskal

2023

Arch Computat Methods Eng

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“…TBCs represent a revolutionary innovation in materials engineering, defining a multilayered system, typically containing an outer ceramic layer placed over a metallic bonding layer, which jointly serves to isolate the component's material from the external environment and to reduce the impacts exerted by it. Not only are they essential for sustainability by extending the lifespan and usage time of systems by protecting components from the adverse effects of high temperatures, large temperature variations, corrosion and oxidation but they also contribute to enhancing the performance of various equipment through isolation of the working environment [2,3].…”

Section: Introductionmentioning

confidence: 99%

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

Bogdan,

Peter

2024

Metals

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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.

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“…In the case of the TC, it has been reported that several materials can be suitable for TBCs, including TiO 2 , ZrO 2 , Al 2 O 3 , kaolinite, and mineral oxides, such as pyrochlores (A 2 + B 2 + O 7 ), as well as garnets, monazites, xenotimes, perovskites (ABO 3), rare earth magnesium hexaaluminate (REMHA), etc., but the most common material used is yttria partially stabilized zirconia (YSZ) [7,[22][23][24][25][26][27][28][29][30]. The main characteristics that promote YSZ as a good ceramic coating are low thermal conductivity, high dielectric constant, high fracture toughness, chemical inertness at high temperatures, and great resistance to thermal shock [31].…”

Section: Introductionmentioning

confidence: 99%

A Study on Long-Term Oxidation and Thermal Shock Performance of Nanostructured YSZ/NiCrAlY TBC with a Less Dense Bond Coat

2023

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This paper focused on studying the performance of a nanostructured thermal barrier coating (TBC) system deposited by APS, which had a bond coat with inter-lamellar porosities that resulted during the manufacturing process. The higher porosity level of the bond coat was studied as a possible way to keep the thickness of the TGO under control, as it is distributed on a higher surface, thereby reducing the chance of top-coat (TC) spallation during long-term oxidation and high-temperature thermal shock. The TBC system consisted of nanostructured yttria partially stabilized zirconia (YSZ) as a top coat and a conventional NiCrAlY bond coat. Inter-lamellar porosities ensured the development of a TGO distributed on a higher surface without affecting the overall coating performance. Based on long-term isothermal oxidation tests performed at 1150 °C, the inter-lamellar pores do not affect the high resistance of nanostructured TBCs in case of long-term iso-thermal oxidation at 1150 °C. The ceramic layer withstands the high-temperature exposure for 800 h of maintaining without showing major exfoliation. Fine cracks were discovered in the ceramic coating after 400 h of isothermal oxidation, and larger cracks were found after 800 h of exposure. An increase in both ceramic and bond-coat compaction was observed after prolonged high-temperature exposure, and this was sustained by the higher adhesion strength. Moreover, in extreme conditions, under high-temperature thermal shock cycles, the TBC withstands for 1242 cycles at 1200 °C and 555 cycles at 1250 °C.

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Multi-Scale Structural Design and Advanced Materials for Thermal Barrier Coatings with High Thermal Insulation: A Review

Cited by 8 publications

References 234 publications

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

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

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

A Study on Long-Term Oxidation and Thermal Shock Performance of Nanostructured YSZ/NiCrAlY TBC with a Less Dense Bond Coat

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