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Coatings
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Current Status of Fundamentals and Applications of Thermal Barrier Coatings
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Current Status of Fundamentals and Applications 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 (10 July 2021) | Viewed by 12788

Special Issue Editor

Dr. Kuiying Chen

E-Mail Website
Guest Editor
National Research Council Canada, Aerospace Research Centre, Ottawa ON, Canada
Interests: gas turbine materials; protective coatings; and multi-scale multi-physics materials modeling

Special Issue Information

Dear colleagues,

We would like to invite you to submit your research work to our Special Issue "Current Status of Fundamentals and Applications of Thermal Barrier Coatings." As an integral part of turbine design, thermal barrier coatings (TBCs) have been applied to hot section components of combustors, high-pressure turbine (HPT) blades, and HPT nozzles for decades in both propulsion and power generation engines. The insulating capability of TBCs enables higher operating temperatures, reduces the amount of cooling air, therefore, improving efficiency, reducing emissions, and increasing thrust. Although our understanding of mechanisms governing TBC performance has improved significantly over the past decades, current engine design primarily relies on the life-extension benefits of TBCs; it does not fully exploit the significant performance improvements that TBCs can provide. The thermal barrier coating prime reliance and advances have long been hindered by TBC failure via various mechanisms. 

This Special Issue will present the latest design and development of thermal barrier coatings (APS-TBCs, EB-PVD TBC, and SPS-TBCs) applied to propulsion and power generation engines through original research papers and review articles from leading scientists and engineers across the world.

In particular, the topics of interest include but not limited to the following:

  • Failure mechanisms and damage mechanics (experiments, numerical, and analytical models);
  • FOD and erosion mechanisms (experiments, numerical, elastodynamics formulae, cutting-deformation-based models, Monte Carlo);
  • Hot corrosion, water vapor, and mitigation approaches of CMAS;
  • Topcoat sintering (testing and multi-scale models) and bond coat /TGO rumpling (testing and models);
  • Lower thermal conductivity of topcoat (new materials, DFT combined phonon theory, mechanics and physics-based models; microscale defect models);
  • New bond coats towards increasing TBC life;
  • Interface and topcoat toughness mechanisms and models;
  • Processing, performance, and economics of TBCs deposition;
  • Residual stress models and the effect of thermal gradient on life and failure behavior (experiments and models);
  • Applications of artificial intelligence, machine learning, and deep learning combining big data in TBC design and development.
Dr. Kuiying Chen
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
  • failure and life prediction
  • FOD and erosion
  • hot corrosion
  • water vapor
  • CMAS
  • thermal conductivity
  • toughness
  • economics

Published Papers (4 papers)

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Research

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35 pages, 4238 KiB  
Article
Application of Machine Learning to Solid Particle Erosion of APS-TBC and EB-PVD TBC at Elevated Temperatures
by Yuan Liu, Ravi Ravichandran, Kuiying Chen and Prakash Patnaik
Coatings 2021, 11(7), 845; https://doi.org/10.3390/coatings11070845 - 13 Jul 2021
Cited by 5 | Viewed by 3303
Abstract
Machine learning (ML) and deep learning (DL) for big data (BD) management are currently viable approaches that can significantly help in high-temperature materials design and development. ML-DL can accumulate knowledge by learning from existing data generated through multi-physics modelling (MPM) and experimental tests [...] Read more.
Machine learning (ML) and deep learning (DL) for big data (BD) management are currently viable approaches that can significantly help in high-temperature materials design and development. ML-DL can accumulate knowledge by learning from existing data generated through multi-physics modelling (MPM) and experimental tests (ETs). DL mainly involves analyzing nonlinear correlations and high-dimensional datasets implemented through specifically designed numerical algorithms. DL also makes it possible to learn from new data and modify predictive models over time, identifying anomalies, signatures, and trends in machine performance, develop an understanding of patterns of behaviour, and estimate efficiencies in a machine. Machine learning was implemented to investigate the solid particle erosion of both APS (air plasma spray) and EB-PVD (electron beam physical vapour deposition) TBCs of hot section components. Several ML models and algorithms were used such as neural networks (NNs), gradient boosting regression (GBR), decision tree regression (DTR), and random forest regression (RFR). It was found that the test data are strongly associated with five key factors as identifiers. Following test data collection, the dataset is subjected to sorting, filtering, extracting, and exploratory analysis. The training and testing, and prediction results are analysed. The results suggest that neural networks using the BR model and GBR have better prediction capability. Full article
(This article belongs to the Special Issue Current Status of Fundamentals and Applications of Thermal Barrier Coatings)
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39 pages, 14157 KiB  
Article
The Effect of Interfacial Roughness on Residual Stresses in Electron Beam-Physical Vapor Deposition of Thermal Barrier Coatings
by Bochun Zhang, Kuiying Chen and Natalie Baddour
Coatings 2021, 11(3), 341; https://doi.org/10.3390/coatings11030341 - 17 Mar 2021
Cited by 2 | Viewed by 1897
Abstract
Residual stresses play an essential role in determining the failure mechanisms and life of an electron beam-physical vapour deposition thermal barrier coating (EB-PVD TBC) system. In this paper, a new transitional roughness model was proposed and applied to describe the interfacial roughness profile [...] Read more.
Residual stresses play an essential role in determining the failure mechanisms and life of an electron beam-physical vapour deposition thermal barrier coating (EB-PVD TBC) system. In this paper, a new transitional roughness model was proposed and applied to describe the interfacial roughness profile during thermal cycles. Finite element models were implemented to calculate residual stresses at specific positions close to the interface of TBCs using temperature process-dependent model parameters. Combining stresses evaluated at valleys of the topcoat (TC) and excessive sharp tip roughness profiles, positions where the maximum out-of-plane residual stresses occur were identified and used to explain possible cracking routes of EB-PVD TBCs as interfacial roughness evolves during thermal cycling. Full article
(This article belongs to the Special Issue Current Status of Fundamentals and Applications of Thermal Barrier Coatings)
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Review

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26 pages, 6724 KiB  
Review
The Effect of High-Temperature Water Vapour on Degradation and Failure of Hot Section Components of Gas Turbine Engines
by Kuiying Chen, Dongyi Seo and Pervez Canteenwalla
Coatings 2021, 11(9), 1061; https://doi.org/10.3390/coatings11091061 - 02 Sep 2021
Cited by 8 | Viewed by 3908
Abstract
For the past decade, the aviation industry has been adopting sustainable aviation fuels (SAF) for use in aircraft to reduce the impact of aviation on climate change. Also, some nations look to SAF as an option for energy security for their military fleets. [...] Read more.
For the past decade, the aviation industry has been adopting sustainable aviation fuels (SAF) for use in aircraft to reduce the impact of aviation on climate change. Also, some nations look to SAF as an option for energy security for their military fleets. Understanding the critical impact of alternative fuel sources on hardware will provide the gas turbine industry with strategic options in sustainability and maintainability of the existing and new fleets. The alternative fuels with high hydrogen/carbon ratio (H/C) (such as synthetic paraffinic kerosenes (SPK)) could produce more water vapour content than the conventional jet fuels upon combustion, and this increased water vapour level could exert a significant impact over the long-term durability on hot section components such as the substrate blades, oxidation resistant coatings, thermal barrier coatings (TBCs), environmental barrier coatings (EBCs), resulting in an accelerated degradation of the turbine components. The possible detrimental effect of high-temperature water vapour on degradation and lifespan of hot section components was examined. Examples were specifically given on degradation and spallation of thermally grown oxides (TGO), formation of non-protective oxides and ceramics topcoats in TBCs. Results show that water vapour can lead to volatilization of TGO (Al2O3), and is responsible for the formation of non-protective oxides in both Pt-modified β-NiAl and MCrAlY coatings, leading to their early spallation. However, water vapour does not appear to directly affect the ceramic topcoat of the TBC. For EBCs coated on SiC-based substrates, the substrate recession via silica (TGO) volatilization was reviewed. These EBCs were observed undergoing degradation in highly hostile environments, e.g., constantly operating under high temperatures, pressures, and velocities condition in the presence of water vapour steam. The review intends to provide a perspective of high-temperature water vapour effect on the EBCs’ topcoat properties such as durability, degradation, crack nucleation and crack growth, and possible guidance for mitigating these degradation effects. Full article
(This article belongs to the Special Issue Current Status of Fundamentals and Applications of Thermal Barrier Coatings)
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19 pages, 3425 KiB  
Review
Test-Rig Simulation on Hybrid Thermal Barrier Coating Assisted with Cooling Air System for Advanced Gas Turbine under Prolonged Exposures—A Review
by Salmi Mohd Yunus, Savisha Mahalingam, Abreeza Manap, Nurfanizan Mohd Afandi and Meenaloshini Satgunam
Coatings 2021, 11(5), 560; https://doi.org/10.3390/coatings11050560 - 10 May 2021
Cited by 8 | Viewed by 2925
Abstract
Thermal barrier coating (TBC) and cooling air systems are among the technologies that have been introduced and applied in pursuing the extensive development of advanced gas turbine. TBC is used to protect the gas turbine components from the higher operating temperature of advanced [...] Read more.
Thermal barrier coating (TBC) and cooling air systems are among the technologies that have been introduced and applied in pursuing the extensive development of advanced gas turbine. TBC is used to protect the gas turbine components from the higher operating temperature of advanced gas turbine, whereas cooling air systems are applied to assist TBC in lowering the temperature exposure of protected surfaces. Generally, a gas turbine operates in three main operational modes, which are base load, peak load, and part peak load. TBC performance under these three operational modes has become essential to be studied, as it will provide the gas turbine owners not only with the behaviors and damage mechanism of TBC but also a TBC life prediction in a particular operating condition. For TBC under base load or so called steady-state condition, a number of studies have been reviewed and discussed. However, it has been found that most of the studies have been conducted without the assistance of a cooling air system, which does not simulate the TBC in advanced gas turbine completely. From this review, the studies on TBC-assisted cooling air system to simulate the advanced gas turbine operating conditions have also been summarized, which are limited to test rig simulations under thermal cyclic mode where thermal cyclic represents peak and part peak load conditions. The equipment used to simulate the gas turbine operating condition, test temperatures, and durations are parameters that have been taken into consideration under this review. Finally, a test rig that is capable of simulating both TBC and cooling air effects at a high operating temperature of advanced gas turbines for prolonged exposure under steady-state condition has been proposed to be developed. Full article
(This article belongs to the Special Issue Current Status of Fundamentals and Applications of Thermal Barrier Coatings)
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