张佩凯,杨会凯,张冲,孙金钊,殷凤仕.热障涂层陶瓷层结构研究现状及发展趋势[J].表面技术,2025,54(5):44-60.
ZHANG Peikai,YANG Huikai,ZHANG Chong,SUN Jinzhao,YIN Fengshi.Research Status and Development Trends of Ceramic Layer Structures in Thermal Barrier Coatings[J].Surface Technology,2025,54(5):44-60 |
| 热障涂层陶瓷层结构研究现状及发展趋势 |
| Research Status and Development Trends of Ceramic Layer Structures in Thermal Barrier Coatings |
| 投稿时间：2024-06-18 修订日期：2024-08-23 |
| DOI：10.16490/j.cnki.issn.1001-3660.2025.05.003 |
| 中文关键词: 热障涂层 陶瓷层结构 双峰结构 双陶瓷结构 功能梯度结构 |
| 英文关键词:thermal barrier coatings ceramic layer structure bimodal structure double ceramic structure functional gradient structure |
| 基金项目:山东省自然科学基金(ZR20191112010) |
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| Author | Institution |
| ZHANG Peikai | School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo 255000, China |
| YANG Huikai | School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo 255000, China |
| ZHANG Chong | School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo 255000, China |
| SUN Jinzhao | School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo 255000, China |
| YIN Fengshi | School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo 255000, China |
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| 中文摘要: |
| 热障涂层(TBC)在先进航空航天发动机的热防护方面发挥着至关重要的作用。新一代航空发动机对温度有着更高的要求，这对当前的热障涂层系统的热防护性能和寿命提出了新的挑战。传统的氧化钇稳定氧化锆(YSZ)热障涂层因其自身的局限性，已经无法满足新一代航空发动机的需要。目前，针对热障涂层的研究主要集中于设计新的TBC架构，在各种不同的设计中，层片状结构、双峰结构、柱状结构、双陶瓷层结构和功能梯度结构已经被证实能够有效提升热障涂层的高温性能和使用寿命。以上述几种不同结构的TBC为切入点，对目前研究较为成熟的几种新型TBC架构进行评价。首先，系统介绍了几种陶瓷层结构的微观组织和制备方法;分析了不同陶瓷层结构的优缺点和适用性。进一步揭示了传统热障涂层的失效机理和局限性;详细分析了不同陶瓷层结构对涂层抗烧结性能和抗热震性能的影响。最后对不同的涂层结构提出了性能改进策略，并针对不同的涂层制备工艺及结构优化方向进行了展望，以期提高热障涂层的性能，满足航空发动机、燃气轮机等高精尖领域未来的使用需求。 |
| 英文摘要: |
| Thermal barrier coatings (TBCs) play a crucial role in thermal protection for advanced aerospace engines. As the thrust-to-weight ratio increases, the thermal endpoint temperature of the engine is further elevated, which in turn raises the demand for high-temperature resistance in engine structural materials. This presents new challenges for the thermal protection performance and service life of existing thermal barrier coating systems. Conventional yttria-stabilized zirconia (YSZ) thermal barrier coatings, due to their inherent limitations, are no longer adequate to meet the requirements of the new generation of aerospace engines. Studies have shown that 8YSZ coatings, when exposed to a working environment of 1 200 ℃ for extended periods, are highly susceptible to sintering. Within the coating, a phase transformation from tetragonal ZrO2 (t-ZrO2) to monoclinic ZrO2 (m-ZrO2) occurs, a process accompanied by a volume change of approximately 3% to 5%. On the one hand, this transformation introduces significant internal stress within the coating, ultimately leading to cracking and spalling of the coating. On the other hand, sintering of the coating at high temperature can lead to the healing of internal pores within the coating, resulting in a significant increase in the Young's modulus of the coating. This, in turn, the thermal insulating performance and service life of the coating are reduced. The design of the ceramic layer structure is a key factor in determining the performance and service life of thermal barrier coatings, and the ongoing research aims to optimize these structures for specific applications and operating conditions. Currently, the research on thermal barrier coatings primarily focuses on designing new TBC architectures. Among various designs, architectures such as lamellar structures, bimodal structures, columnar structures, dual-ceramic layers, and functionally graded structures have been demonstrated to effectively enhance the high temperature performance and service life of thermal barrier coatings. Several maturely researched novel TBC architectures are evaluated, with the aforementioned different structures of TBCs as the starting point. Firstly, a summary of the current research status and types of commonly used ceramic topcoat structures is provided, followed by a systematic introduction to the microstructures and fabrication methods of several ceramic layer structures. The advantages, disadvantages, and applicability of different ceramic layer structures are analyzed. Furthermore, the failure mechanisms and limitations of conventional thermal barrier coatings are revealed, and an in-depth analysis of the existing ceramic topcoat structures is conducted in terms of sintering resistance and thermal shock resistance, thereby elucidating the mechanisms by which different ceramic topcoat structures affect performance. Finally, strategies for improving the performance of various coating structures are proposed, and prospects for different coating fabrication techniques and structural optimization directions are discussed, providing a theoretical basis for the advancement and development of advanced gas turbines. The aim is to enhance the performance of thermal barrier coatings to meet the future requirements of high-end fields such as aerospace engines and gas turbines. |
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