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Coatings
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Coatings for Extreme Environments
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Coatings for Extreme Environments

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 (20 October 2022) | Viewed by 9056

Special Issue Editors

Dr. Kang N. Lee

E-Mail Website
Guest Editor
NASA Glenn Research Center, Cleveland, USA
Interests: environmental barrier coatings; thermal barrier coatings; high temperature oxidation; high temperature materials chemistry; solid-state batteries
Special Issues, Collections and Topics in MDPI journals
Dr. Yuk-Chiu (Y.C.) Lau

E-Mail Website
Guest Editor
Retired Technical Leader-Coating Technology & Development, GE Power, Ballston Lake, NY, USA
Interests: thermal barrier coatings (TBCs); abradable coatings; environmental barrier coatings for land-based gas turbines and aircraft engines

Special Issue Information

Dear Colleagues,

Surface coatings have become an integral part of advanced materials. Surface coatings enhance material performance by providing protection from extreme environments such as high temperature, high stress, siliceous debris (sand and volcanic ash), oxidizing and corrosive species, and erosive environments. Thermal and environmental barrier coatings are enabling technologies for superalloy and ceramic matrix composite (CMC) components. Tribological coatings improve the life of components in erosive environments. Various coatings are used to improve the functionality of components. This Special Issue invites articles on the processing, characterization, and performance of coatings produced by a wide variety of technologies that encompass thermal spray (plasma spray, HVOF, etc.), kinetic based spray processes (cold spray, aerosol deposition, etc.), physical vapor deposition (EB-PVD, PS-PVD, etc.), chemical vapor deposition, and solution-based processes (slurry, sol–gel, etc.). Topics of focus include new innovations in materials and process technology, testing and evaluation, modeling, lifting, and emerging applications.

Dr. Kang N. Lee
Dr. Yuk-Chiu (Y.C.) Lau
Guest Editors

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.

Published Papers (4 papers)

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Research

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21 pages, 7218 KiB  
Article
Novel Thermal Barrier Coatings with Phase Composite Structures for Extreme Environment Applications: Concept, Process, Evaluation and Performance
by Xinqing Ma, Kristina Rivellini, Peter Ruggiero and George Wildridge
Coatings 2023, 13(1), 210; https://doi.org/10.3390/coatings13010210 - 16 Jan 2023
Cited by 5 | Viewed by 2484
Abstract
In this paper, a novel concept in the field of phase composite ceramics has been proposed and applied for creating the topcoats of durable thermal barrier coatings (TBCs), which is one of the most critical technologies for advanced high-efficiency gas turbine engines in [...] Read more.
In this paper, a novel concept in the field of phase composite ceramics has been proposed and applied for creating the topcoats of durable thermal barrier coatings (TBCs), which is one of the most critical technologies for advanced high-efficiency gas turbine engines in extreme environments. The phase composite ceramic TBCs were designed to demonstrate superior and comprehensive performance-related merits, benefits, and advantages over conventional single-phase TBCs with a topcoat of 8YSZ or Gd2Zr2O7, including thermal phase stability, thermal shock durability, low thermal conductivity, and solid particle erosion resistance. In this paper, we review and summarize the development work conducted so far related to the phase composite ceramic concept, coatings processing, and experimental investigation into TBC behaviors at elevated temperatures (typically, ≥1250 °C) using different evaluation and characterization methods, including isothermal sintering, a burner rig test, a solid particle-impinging erosion test, and a CMAS corrosion test. Two-phase (t’+c) zirconia-based TBCs demonstrated improved thermal shock and erosion resistance in comparison to conventional single-phase (t’), 8YSZ TBC, and Gd2Zr2O7 TBC, when used separately. Additionally, a triple-phase (t’+c+YAG) TBC sample demonstrated superior CMAS resistance. The TBC’s damage modes and failure mechanisms for thermal phase stability, thermal cycling resistance, solid particle erosion behavior, and CMAS infiltration are also characterized and discussed in detail, in terms of microstructural characterization and performance evaluation. Full article
(This article belongs to the Special Issue Coatings for Extreme Environments)
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14 pages, 5753 KiB  
Article
Manufacturing Process Development and Rig Validation of Slurry Environmental Barrier Coatings for SiC Ceramic and SiC Composite Sub-Components
by Kang N. Lee, Bryan J. Harder, Bernadette J. Puleo, Amjad S. Almansour, James D. Kiser, John A. Setlock, Dennis S. Fox, Michael D. Cuy, Sreeramesh Kalluri and Ramakrishna T. Bhatt
Coatings 2022, 12(11), 1635; https://doi.org/10.3390/coatings12111635 - 28 Oct 2022
Cited by 5 | Viewed by 1579
Abstract
The process scale-up of fully oxide-based environmental barrier coatings (EBCs) on sintered SiC and chemical vapor infiltration (CVI) SiC/SiC ceramic matrix composite (CMC) sub-components was investigated using various slurry manufacturing processes (dip, spray, spin–dip). The performance of EBC-coated sub-components (SiC heating element, SiC/SiC [...] Read more.
The process scale-up of fully oxide-based environmental barrier coatings (EBCs) on sintered SiC and chemical vapor infiltration (CVI) SiC/SiC ceramic matrix composite (CMC) sub-components was investigated using various slurry manufacturing processes (dip, spray, spin–dip). The performance of EBC-coated sub-components (SiC heating element, SiC/SiC ceramic matrix mini-composite, SiC airfoil, SiC/SiC CMC airfoil) was evaluated in steam oxidation and combustion rigs. Steam oxidation was conducted at 1427 °C in 90 vol.% H2O (g) + 10 vol.% O2 (g) with a 1 h hold at 1427 °C per cycle (1 h hot and 20 min cooling). For high-pressure combustion rig testing, the EBC surface temperature ranged between 1354 °C and 1538 °C with the temperature gradient through CMC + EBC ranging between 100 °C and 150 °C. Dip and spin–dip are non-line-of-sight processes, whereas spray is a line-of-sight process. The three processes, collectively, demonstrated the capability to manufacture slurry EBCs on sub-components with various shapes and sizes. There was no discernable disparity in the EBC steam oxidation performance between the coupons and sub-components in this study and coupons in a previous study. The dependence of steam oxidation rates on the substrate chemistry reported previously was confirmed. The steam oxidation rate of EBC-coated sintered SiC, compared with EBC-coated CVI CMC, was ~2 times and ~1.5 times higher after 100 h and 500 h, respectively, due to the boron sintering aid in sintered SiC. An EBC-coated CMC airfoil after 150 15-h-long cycles in a high-pressure combustion rig test showed only limited EBC spallation along the leading edge and more substantial spallation along the trailing edge, demonstrating the feasibility of an oxide-based bond coat to meet the extreme temperature requirements of next-generation EBCs. Full article
(This article belongs to the Special Issue Coatings for Extreme Environments)
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12 pages, 6800 KiB  
Article
Thermal Cycling Behavior of Air Plasma-Sprayed and Low-Pressure Plasma-Sprayed Environmental Barrier Coatings
by Dianying Chen, Aaron Pegler, Gopal Dwivedi, Daniel De Wet and Mitchell Dorfman
Coatings 2021, 11(7), 868; https://doi.org/10.3390/coatings11070868 - 20 Jul 2021
Cited by 16 | Viewed by 3418
Abstract
Yb2Si2O7/Si environmental barrier coatings (EBCs) were produced by air plasma spray (APS) and low-pressure plasma spray (LPPS) processes. The phase composition, microstructure, and bonding strength of APS and LPPS EBCs were investigated. Thermal cycling tests were performed [...] Read more.
Yb2Si2O7/Si environmental barrier coatings (EBCs) were produced by air plasma spray (APS) and low-pressure plasma spray (LPPS) processes. The phase composition, microstructure, and bonding strength of APS and LPPS EBCs were investigated. Thermal cycling tests were performed in air and in steam atmosphere respectively at 1316 °C for both APS and LPPS EBCs. There is no coating failure in air atmosphere for both APS and LPPS EBCs after 900 cycles. In contrast, APS EBCs have an average life of 576 cycles in a steam cycling test in 90% H2O + 10% air at 1316 °C while LPPS EBCs survived 1000 cycles without failure. The superior durability of the LPPS EBCs compared to APS EBCs in the same steam cycling environment is attributed to the significantly reduced thermally grown oxide (TGO) growth rate because of the denser and crack-free microstructure, higher bonding strength, and reduced coefficient of thermal expansion (CTE) mismatch (less Yb2SiO5 phase) in the LPPS Yb2Si2O7/Si EBCs. Full article
(This article belongs to the Special Issue Coatings for Extreme Environments)
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Review

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21 pages, 4752 KiB  
Review
Sintering Modeling of Thermal Barrier Coatings at Elevated Temperatures: A Review of Recent Advances
by Jinrong Yan, Xin Wang, Kuiying Chen and Kang N. Lee
Coatings 2021, 11(10), 1214; https://doi.org/10.3390/coatings11101214 - 03 Oct 2021
Cited by 16 | Viewed by 3053
Abstract
To achieve a higher efficiency in gas turbine engine by increasing the inlet-temperature of burning gas is one of the primary goals in aviation industry. The development of thermal barrier coating system (TBCs) continuously raises the inlet-temperature of gas turbine engine in the [...] Read more.
To achieve a higher efficiency in gas turbine engine by increasing the inlet-temperature of burning gas is one of the primary goals in aviation industry. The development of thermal barrier coating system (TBCs) continuously raises the inlet-temperature of gas turbine engine in the past decades. Due to the complexity of TBCs and harsh operation environments, the degradation and failure mechanisms of hot section components have not been fully understood, and consequently limits the application of TBCs. It was identified that high-temperature sintering of the topcoat in a typical TBC could be one of the major sources of its failure since the microstructures of the constituent coating layers evolve dynamically during the service period, resulting in significant changes of mechanical and thermal physical properties of the coating system. This paper intends to review recent advances of analytical and numerical modeling of sintering of topcoat in TBCs including the modeling methodology and applications of the models, particularly the implementation of finite element combined with specific materials constitutive functions. Critical remarks on the future development and applications of these models are also discussed in the end. Full article
(This article belongs to the Special Issue Coatings for Extreme Environments)
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