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Recent Advances in the Materials, Preparations, and Properties of Thermal...
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Recent Advances in the Materials, Preparations, and Properties 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: 20 October 2024 | Viewed by 3248

Special Issue Editor

Prof. Dr. Xiaofeng Zhao

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, China
Interests: thermal barrier coatings

Special Issue Information

Dear Colleagues,

Thermal Barrier Coatings (TBCs) have emerged as a critical enabler of innovation in industries like aerospace, energy production, automotive, and manufacturing. These specialized coatings serve as protective shields, safeguarding vital components against the ravages of high-temperature environments. By providing a robust thermal insulating barrier, TBCs ensure the efficient operation and extended lifespan of machinery and structures, ultimately translating into significant economic and environmental benefits.

In recent years, the quest for novel materials, innovative manufacturing methods, and enhanced performance has led to an ever-evolving landscape of TBC technology. Thus, we aim to gather contributions from experts and researchers in the TBC domain, highlighting key advancements, challenges, and future prospects.

This Special Issue is intended to serve as a comprehensive collection of cutting-edge research and developments in the field of TBC for researchers, engineers, and professionals to access the latest insights and innovations.

In this Special Issue, original research articles and reviews are welcome. Research areas may include (but are not limited to) the following:

  • Synthesis and characterization of novel materials with superior thermal insulation properties and high-temperature stability;
  • Innovative manufacturing techniques, such as advanced deposition processes, additive manufacturing (3D printing), and surface modification techniques;
  • Multifunctional TBCs that not only provide thermal protection but also offer additional capabilities such as erosion resistance, corrosion protection, self-healing, or electrical conductivity;
  • Challenges associated with TBC durability and exploring advances in new strategies;
  • State-of-the-art methods for characterizing and testing TBCs;
  • Applications of TBCs in sectors like aerospace, gas turbine engines, renewable energy systems, industrial processing, and so on;
  • Eco-friendly approaches in TBC development.

We look forward to receiving your contributions.

Prof. Dr. Xiaofeng Zhao
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.

Keywords

  • thermal barrier coatings
  • yttria stabilized zirconia
  • plasma spray
  • physical vapour deposition
  • high-temperature oxidation
  • thermal conductivity
  • failure mechanisms
  • durability
  • corrosion resistance
  • mechanical properties

Published Papers (4 papers)

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Research

13 pages, 4202 KiB  
Article
Interfacial Stability between High-Entropy (La0.2Yb0.2Sm0.2Eu0.2Gd0.2)2Zr2O7 and Yttria-Stabilized Zirconia for Advanced Thermal Barrier Coating Applications
by Guojie Yang, Chenbing Han, Ying Chen, Fangwei Guo, Jie Lu, Ming Zhou, Lirong Luo and Xiaofeng Zhao
Coatings 2024, 14(3), 269; https://doi.org/10.3390/coatings14030269 - 22 Feb 2024
Viewed by 666
Abstract
(La0.2Yb0.2Sm0.2Eu0.2Gd0.2)2Zr2O7 (HEZ) has shown considerable promise as a novel thermal barrier coating material for temperatures exceeding 1300 °C. This study systematically investigates the interfacial stability of (La0.2 [...] Read more.
(La0.2Yb0.2Sm0.2Eu0.2Gd0.2)2Zr2O7 (HEZ) has shown considerable promise as a novel thermal barrier coating material for temperatures exceeding 1300 °C. This study systematically investigates the interfacial stability of (La0.2Yb0.2Sm0.2Eu0.2Gd0.2)2Zr2O7 with yttria-stabilized zirconia (YSZ), which is of paramount importance for its application in double-layer thermal barrier coatings. Our findings highlight that rare earth elements with a smaller radius diffuse more easily into the YSZ lattice, resulting in a broader diffusion zone. Simultaneously, the incorporation of rare earth elements into the YSZ lattice inhibits tetragonal-to-monoclinic phase transformation. Compared to La2Zr2O7/YSZ, HEZ/YSZ demonstrates superior high-temperature stability, which could be attributed to the higher fracture toughness and lower thermal expansion coefficient of HEZ, the absence of t-m transformation and the formation of a continuous gradient diffusion layer that minimizes interface stress. This study offers a practical strategy for designing materials for durable double-layer thermal barrier coating systems. Full article
(This article belongs to the Special Issue Recent Advances in the Materials, Preparations, and Properties of Thermal Barrier Coatings)
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20 pages, 17667 KiB  
Article
Determination of Critical Velocity of Cold-Sprayed NiCoCrAlY Coating via Arbitary Lagrangian-Eulerian (ALE) Method of Finite Element Simulation
by Qian Wu, Jiahui Su, Weiling Zhao, Jiaxue Li, Ke Zhang and Liang Wang
Coatings 2023, 13(12), 1992; https://doi.org/10.3390/coatings13121992 - 23 Nov 2023
Viewed by 787
Abstract
NiCoCrAlY coatings are commonly used as bond-coat in thermal barrier coatings due to their excellent high-temperature oxidation resistance and suitable thermal expansion coefficient between the superalloy substrate and ceramic top layer. Previous studies have shown that the NiCoCrAlY coatings prepared by cold spray [...] Read more.
NiCoCrAlY coatings are commonly used as bond-coat in thermal barrier coatings due to their excellent high-temperature oxidation resistance and suitable thermal expansion coefficient between the superalloy substrate and ceramic top layer. Previous studies have shown that the NiCoCrAlY coatings prepared by cold spray (CS) exhibit excellent comprehensive properties. In the process of cold spray, the solid particles impact onto the substrate with a high velocity, powder particles and the substrate undergo plastic deformation, and the coating is deposited finally. When the velocity of the impacted particles reaches a certain value (critical velocity), the particles can be effectively deposited on the substrate. Due to the short impact time and large plastic deformation of the cold spray process, the process is difficult to be observed in the actual experiment process in real time. Therefore, the current work has used the explicit dynamics method in finite element numerical simulation to simulate the deposition behavior of the particle during the cold spray process. By changing the impact velocities and sizes of particles, the changes in temperature (TEMP), equivalent plastic strain (PEEQ), deformation characteristics of the particle and substrate after particles being completely deposited on the substrate have been obtained. The critical velocity of particle deposition is about 600 m/s, and the larger the particle, the easier it is to deposit. And the current modeling and simulation work provided the theory instruction for the preparation of NiCoCrAlY coatings with excellent performance via cold spray. Full article
(This article belongs to the Special Issue Recent Advances in the Materials, Preparations, and Properties of Thermal Barrier Coatings)
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11 pages, 8651 KiB  
Article
Effects of Top Ceramic Layers with an Ultrathin Dense Layer on the Thermal–Physical Properties of Thermal Barrier Coatings
by Li Ai, Xueying Wang, Ming Yang, Yuntao Lei and Yongping Zhu
Coatings 2023, 13(11), 1929; https://doi.org/10.3390/coatings13111929 - 11 Nov 2023
Viewed by 730
Abstract
Thermal barrier coatings have been used to protect superalloys under extremely harsh conditions. The durability of TBCs with a NiCoCrAlY bond layer prepared via the air plasma spray process and an ultrathin dense layer prepared via magnetron sputtering was investigated under different corrosion [...] Read more.
Thermal barrier coatings have been used to protect superalloys under extremely harsh conditions. The durability of TBCs with a NiCoCrAlY bond layer prepared via the air plasma spray process and an ultrathin dense layer prepared via magnetron sputtering was investigated under different corrosion conditions. This paper discusses the corrosion resistance improvement mechanism of TBCs with a dense layer produced by magnetron sputtering under corrosion conditions with environmental contaminants such as calcium–magnesium–aluminum–silicon oxide systems (CMAS) at 1300 °C and NaCl-Na2SO4-V2O5 (NV) at 900 °C. The corrosion results show that CMAS will react with the stabilizers of zirconium oxide, which will change the rate of the phase transition, as determined via X-ray diffraction tests. A thermal ablation test verified that TBCs with a dense layer have a better corrosion resistance and better thermal insulation properties. All results show that preparing TBCs with a dense layer via the magnetron sputtering method will be an efficient method to improve TBCs’ properties at high temperatures in the future. Full article
(This article belongs to the Special Issue Recent Advances in the Materials, Preparations, and Properties of Thermal Barrier Coatings)
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16 pages, 6076 KiB  
Article
Effect of Top-Coat Thickness and Interface Fluctuation on the Residual Stress in APS-TBCs
by Weiling Zhao, Zhongchao Hu, Liang Wang, Xintong Wang, Qihao Wu and Runpin Liu
Coatings 2023, 13(9), 1659; https://doi.org/10.3390/coatings13091659 - 21 Sep 2023
Viewed by 792
Abstract
This study focused on the numerical simulation of the distribution of residual stress in yttria-stabilized zirconia (YSZ) coatings prepared with atmospheric plasma spraying (APS). We particularly investigated the stress distribution around the interface between the top coat and bond coat. During thermal spray [...] Read more.
This study focused on the numerical simulation of the distribution of residual stress in yttria-stabilized zirconia (YSZ) coatings prepared with atmospheric plasma spraying (APS). We particularly investigated the stress distribution around the interface between the top coat and bond coat. During thermal spray deposition, droplets and particles deposit on the substrate in a complex manner, causing interface waviness and non-uniform stress distribution. Therefore, residual stress is an important consideration when preparing thermal barrier coatings (TBCs). Residual stresses directly affect the performance of bond coats (BCs) and ceramic top coats (TCs). To accurately evaluate residual stress, we considered interface waviness and the thickness of the ceramic top coat and conducted a detailed analysis of stress distribution. The results show that compressive stress exists at the TC/BC interface, which may be caused by the mismatch in the thermal expansion coefficient between the YSZ top coat and the substrate, potentially leading to coating delamination. Moreover, the residual stress at the TC/BC interface significantly increases with an increasing YSZ thickness. When the top-coat thickness exceeds 300 μm, stress concentration and failure of the coating are likely to occur. Meanwhile, the optimized thermal spray experiment results confirm that the residual stress at the BC/YSZ interface of the thermal barrier coating is tensile stress, with a maximum value of 155 MPa, which is consistent with the finite element calculation results. Furthermore, the failure modes of TBCs with rough interface conditions are discussed in detail. Our research provides important guidance for TBC design and optimizing their performance. Full article
(This article belongs to the Special Issue Recent Advances in the Materials, Preparations, and Properties of Thermal Barrier Coatings)
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