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Coatings
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Recent Developments of Thermal Barrier Coatings
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Recent Developments of Thermal Barrier Coatings

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Surface Characterization, Deposition and Modification".

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 18858

Special Issue Editor

Dr. Nicholas Curry

E-Mail Website
Guest Editor
Treibacher Industrie AG Research and Development, Auer-von-Welsbach-Straße 1, 9330 Althofen, Austria
Interests: thermal barrier coatings (TBC); thermal conductivity, mechanical behavior of materials; thermal spray; advanced materials, suspension plasma spray, environmental barrier coatings

Special Issue Information

Dear Colleagues,

Thermal barrier coatings (TBCs) have been an established part of aero and industrial gas turbines for several decades. Coatings, once thought of as a band-aid measure, are now moving to the point of being a critical life-limiting aspect of turbine design. While an established field, TBCs are still an area of strong active research and development.

New application methods are coming to the forefront of coating development. One example is suspension plasma spray, which is becoming another method when it comes to coating production, complimenting existing electron beam-physical vapor deposition and air plasma spray technologies.

As operational temperatures within turbines are increased to improve power and efficiency, new coating challenges are being encountered. Advanced coating chemistries are required to realize higher operational temperatures. However, increased operational temperatures bring new issues in the form of calica-magnesia-aluminosilicate degradation of coatings. Industrial turbines are wrestling with problems of new operating profiles where combustion of dirty fuels or high hydrogen content gasses are affecting the performance of TBC systems. Finally, as we move to a more ceramic engine, with the introduction of ceramic matrix composite turbine components, it is recognized that extracting the highest performance from these CMC components will also require the development of suitable thermal barrier coatings.

This Special Issue of Coatings will focus on developments in the field of thermal barrier coatings. In particular, the topics of interest include, but are not limited to the following:

  • Developments in application technology for improved coating performance;
  • Development of more efficient processing to reduce environmental impact;
  • New thermal barrier coating chemistries and their performance;
  • Novel coating structures;
  • CMAS mitigation through coating design;
  • Suspension plasma spray for TBC application
  • Development of alternative coating production methods;
  • New bond coat developments for TBCs;
  • TBCs for corrosive or hydrogen combustion environments;
  • Thermal barrier coatings for CMC components;

Dr. Nicholas Curry
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Coatings is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

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Published Papers (4 papers)

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Research

11 pages, 3243 KiB  
Article
Study on the Characteristics of a TBC System Containing a PVD-Al Interlayer under Isothermal Loading
by Ibrahim Ali, Paweł Sokołowski, Lech Pawłowski, Daniel Wett, Thomas Grund and Thomas Lampke
Coatings 2021, 11(8), 887; https://doi.org/10.3390/coatings11080887 - 26 Jul 2021
Cited by 6 | Viewed by 2587
Abstract
In this work, the oxidation behavior of an atmospheric plasma-sprayed thermal barrier coating (TBC) system with a thin Al physical vapor deposition (PVD) film deposited over the bond coat is discussed. The TBC consisted of: (i) CoNiCrAlY bond coat sprayed on the Inconel [...] Read more.
In this work, the oxidation behavior of an atmospheric plasma-sprayed thermal barrier coating (TBC) system with a thin Al physical vapor deposition (PVD) film deposited over the bond coat is discussed. The TBC consisted of: (i) CoNiCrAlY bond coat sprayed on the Inconel 600 substrate; (ii) a thin Al interlayer deposited by direct current DC magnetron sputtering; and (iii) yttria-stabilized zirconia (YSZ) sprayed as the top coat. Such thermal barrier coatings (Al-TBC) were isothermally oxidized at 1150 °C with different holding times, and then they were compared with the reference TBC (R-TBC) systems without an Al interlayer (R-TBC). Scanning electron microscopy with energy-dispersive X-ray analysis was used to study the oxide formation along the bond coat (BC) and top coat (TC) interface, as well as crack formation in the yttria-stabilized zirconia top coat. Then, using Image Analysis, the oxide formation and crack formation were characterized in all specimens after a slow heating and cooling cycle, and after 100, 300, and 600 h of isothermal exposure. The results showed that the Al-TBC system proposed here exhibits higher oxidation resistance at the bond coat and top coat interface, less crack formation in the YSZ top coat, and enhanced mechanical stability compared to the conventional TBCs. It was found that enrichment of the bond coat and top coat interface with Al limited the formation of detrimental transition metal oxides during isothermal loading. Finally, the corresponding failure caused by thermally grown oxide (TGO) phenomena is “mixed failure mode” for both studied TBCs. Full article
(This article belongs to the Special Issue Recent Developments of Thermal Barrier Coatings)
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21 pages, 10113 KiB  
Article
Erosion Performance of Atmospheric Plasma Sprayed Thermal Barrier Coatings with Diverse Porosity Levels
by Satyapal Mahade, Abhilash Venkat, Nicholas Curry, Matthias Leitner and Shrikant Joshi
Coatings 2021, 11(1), 86; https://doi.org/10.3390/coatings11010086 - 14 Jan 2021
Cited by 24 | Viewed by 4099
Abstract
Thermal barrier coatings (TBCs) prolong the durability of gas turbine engine components and enable them to operate at high temperature. Several degradation mechanisms limit the durability of TBCs during their service. Since the atmospheric plasma spray (APS) processed 7–8 wt.% yttria stabilized zirconia [...] Read more.
Thermal barrier coatings (TBCs) prolong the durability of gas turbine engine components and enable them to operate at high temperature. Several degradation mechanisms limit the durability of TBCs during their service. Since the atmospheric plasma spray (APS) processed 7–8 wt.% yttria stabilized zirconia (YSZ) TBCs widely utilized for gas turbine applications are susceptible to erosion damage, this work aims to evaluate the influence of their porosity levels on erosion behavior. Eight different APS TBCs were produced from 3 different spray powders with porosity ranging from 14% to 24%. The as-deposited TBCs were examined by SEM analysis. A licensed software was used to quantify the different microstructural features. Mechanical properties of the as-deposited TBCs were evaluated using micro-indentation technique. The as-deposited TBCs were subjected to erosion tests at different angles of erodent impact and their erosion performance was evaluated. Based on the results, microstructure-mechanical property-erosion performance was correlated. Findings from this work provide new insights into the microstructural features desired for improved erosion performance of APS deposited YSZ TBCs. Full article
(This article belongs to the Special Issue Recent Developments of Thermal Barrier Coatings)
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25 pages, 7722 KiB  
Article
High-Porosity Thermal Barrier Coatings from High-Power Plasma Spray Equipment—Processing, Performance and Economics
by Nicholas Curry, Matthias Leitner and Karl Körner
Coatings 2020, 10(10), 957; https://doi.org/10.3390/coatings10100957 - 4 Oct 2020
Cited by 26 | Viewed by 4292
Abstract
High-porosity thermal barrier coatings are utilized on gas turbine components where maximizing the coating thermal insulation capability is the primary design criteria. Though such coatings have been in industrial use for some time, manufacturing high-porosity coatings quickly and efficiently has proven challenging. With [...] Read more.
High-porosity thermal barrier coatings are utilized on gas turbine components where maximizing the coating thermal insulation capability is the primary design criteria. Though such coatings have been in industrial use for some time, manufacturing high-porosity coatings quickly and efficiently has proven challenging. With the industry demand to increase productivity and reduce waste generation, there is a drive to look at improved coating manufacturing methods. This article looks at high-porosity coatings manufactured using a high-power plasma system in comparison with a current industrial coating. A commercial spray powder is compared with an experimental Low-Density powder developed to maximize coating porosity without sacrificing coating deposition efficiency. The resultant coatings have been assessed for their microstructure, adhesion strength, furnace cyclic lifetime, thermal conductivity and sintering behavior. Finally, the impact of spray processing on coating economics is discussed. The use of a Low-Density powder with a high-power plasma system allows a high-porosity coating to be manufactured more efficiently and more cost effectively than with conventional powder feedstock. The improvement in thermal properties for the experimental coating demonstrates there is scope to improve industrial coatings by designing with specific thermal resistance rather than thickness and porosity as coating requirements. Full article
(This article belongs to the Special Issue Recent Developments of Thermal Barrier Coatings)
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18 pages, 4062 KiB  
Article
Perspectives on Thermal Gradients in Porous ZrO2-7–8 wt.% Y2O3 (YSZ) Thermal Barrier Coatings (TBCs) Manufactured by Air Plasma Spray (APS)
by Rogerio S. Lima
Coatings 2020, 10(9), 812; https://doi.org/10.3390/coatings10090812 - 22 Aug 2020
Cited by 30 | Viewed by 5756
Abstract
Porous (~10–20%) ZrO2-7–8 wt.% Y2O3 (YSZ) thermal barrier coatings (TBCs) manufactured via air plasma spray (APS) and exhibiting a thickness range of ~250–500 µm, provide thermal insulation from the hot combustion gases to the metallic parts located in [...] Read more.
Porous (~10–20%) ZrO2-7–8 wt.% Y2O3 (YSZ) thermal barrier coatings (TBCs) manufactured via air plasma spray (APS) and exhibiting a thickness range of ~250–500 µm, provide thermal insulation from the hot combustion gases to the metallic parts located in the hot stationary sections of gas turbine engines (e.g., combustion chambers of aerospace turbines). The objective of this paper was to measure and report the thermal gradient values in a benchmark porous (~15%) APS YSZ TBC, working within the known acceptable maximum temperature envelop conditions of a TBC/substrate system, i.e., T-ysz ~1300 °C and T-sub ~1000 °C. In order to accomplish this objective, the following steps were performed. A benchmark APS YSZ TBC exhibiting two distinct thicknesses (~260 and ~460 µm) was manufactured. In addition, a thermal gradient laser-rig was employed to generate a temperature drop (ΔT) along the coated coupon, with the target operate within the acceptable maximum temperature capabilities of this type of TBC/substrate architecture. This target was achieved, i.e., T-ysz values were not higher than ~1300 °C while the substrate temperatures did not reach values above ~1000 °C. The ΔTs for the ~260 and ~460 µm YSZ TBCs were ~280 and ~465 °C, respectively. The thermal gradient value for both YSZ TBCs was ~0.90 °C/µm, which falls within those reported in the literature for porous APS YSZ TBCs. Full article
(This article belongs to the Special Issue Recent Developments of Thermal Barrier Coatings)
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