| ZHANG Peikai,YANG Huikai,ZHANG Chong,SUN Jinzhao,YIN Fengshi.Research Status and Development Trends of Ceramic Layer Structures in Thermal Barrier Coatings[J],54(5):44-60 |
| Research Status and Development Trends of Ceramic Layer Structures in Thermal Barrier Coatings |
| Received:June 18, 2024 Revised:August 23, 2024 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2025.05.003 |
| KeyWord:thermal barrier coatings ceramic layer structure bimodal structure double ceramic structure functional gradient structure |
| Author | Institution |
| ZHANG Peikai |
School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo , China |
| YANG Huikai |
School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo , China |
| ZHANG Chong |
School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo , China |
| SUN Jinzhao |
School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo , China |
| YIN Fengshi |
School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo , China |
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| Abstract: |
| 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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