| YANG Ziyi,FU Yongqiang,WANG Youqiang,GU Yanqi,HUANG Shuyuan,MENG Fengyun.Research Progress on YSZ-based Thermal Barrier Coatings[J],54(5):27-43 |
| Research Progress on YSZ-based Thermal Barrier Coatings |
| Received:June 13, 2024 Revised:August 29, 2024 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2025.05.002 |
| KeyWord:thermal barrier coatings yttria partially stabilized zirconia YSZ doping modification coating preparation techniques coating failure |
| Author | Institution |
| YANG Ziyi |
School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao , China |
| FU Yongqiang |
School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao , China |
| WANG Youqiang |
School of Mechanical and Automotive Engineering, Qingdao University of Technology, Shandong Qingdao , China |
| GU Yanqi |
Research Institute of Aero-Engine, Beihang University, Beijing , China |
| HUANG Shuyuan |
Shandong Liangshan Hengtong Machinery Manufacturing Limited Corporation, Shandong Jining , China |
| MENG Fengyun |
Shandong Liangshan Hengtong Machinery Manufacturing Limited Corporation, Shandong Jining , China |
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| Abstract: |
| With the relentless pursuit of higher efficiency in aviation, the turbine inlet temperature of aero-engines has been pushing the boundaries, necessitating superior thermal insulation capabilities from hot-end components. Thermal barrier coatings (TBCs), particularly those based on Yttria Stabilized Zirconia (YSZ), have emerged as a pivotal technology for enhancing the thermal resistance and lifespan of turbine blades. The work aims to delve into the research progress of YSZ-based TBCs, providing a detailed analysis of the modification methods, preparation techniques, and failure mechanisms of the coatings. The effects of coating design by doping of rare earth elements or non-rare earth oxides on the thermal conductivity, high-temperature phase stability, and resistance to sintering of YSZ-based coatings are comprehensively discussed in the review. Additionally, a detailed exploration is provided, clarifying the modification mechanisms and significant impacts that single oxide doping and multi-oxide co-doping have on the properties of YSZ-based coatings. The intricate relationship between the atomic mass, ionic radius, and the resultant phonon scattering has been elucidated, providing a theoretical foundation for the design of low thermal conductivity ceramics. The common YSZ-based coating preparation techniques are introduced, including atmospheric plasma spraying (APS), electron beam physical vapor deposition (EB-PVD), and plasma spray-physical vapor deposition (PS-PVD), and their advantages and disadvantages are summarized. APS YSZ-based coatings offer low thermal conductivity due to their porous, layered structure but have issues with low elasticity, weak adhesion, and limited thermal cycle life. EB-PVD YSZ has a robust columnar structure with high strength but the highest thermal conductivity and is susceptible to high-temperature oxidation and corrosion. PS-PVD merges the benefits of the both, enabling the adjustment of the microstructure for rapid, uniform, and dense coating deposition by varying process parameters. In addition, the primary failure modes of TBCs, including thermal expansion coefficient mismatch, thermally grown oxide (TGO) growth, Calcium-Magnesium-Alumino-Silicate (CMAS) corrosion, and molten salt corrosion by Na2SO4+V2O5, are discussed, along with the corresponding failure mechanisms. The mismatch of thermal expansion coefficients among the bond coat, ceramic layer, and TGO may induce thermally induced stress, which can promote crack extension and lead to spallation. The study of TGO growth is particularly crucial as it can significantly alter the stress intensity and distribution, resulting in the initiation of cracks within the coating. CMAS is capable of penetrating the porous structure of TBCs and reacting with the coating, depleting the yttrium element and forming monoclinic zirconia, thus accelerating the failure of the coating. The corrosion by Na2SO4+V2O5 is especially severe in environments with high concentrations of vanadium and sulfur, where Na2SO4+V2O5 can react with the coating material at high temperature, leading to a loss of adhesion and increased susceptibility to spallation. The interplay between these factors and their synergistic impact on coating degradation is discussed, highlighting the need for a comprehensive understanding to foster the development of robust TBCs. Currently, YSZ-based TBCs have made significant advancements, yet the path to optimization remains challenging. Future research directions are expected to focus on optimizing existing dopant combinations and exploring new stabilizers, integrating experimental and computational approaches, and developing smart maintenance strategies. |
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