Research Progress on High-temperature Failure Mechanism and Efficiency Enhancement Strategy of Thermal Barrier Coatings

• • At 1200 °C thermal cycling, BPS coatings survive 250 cycles without spallation, whereas 8YSZ fails at 150 cycles—a ≥67% lifetime extension. This directly reduces unplanned turbine shutdowns and maintenance intervals, critical for power generation and aviation fleets. • • Vacuum heat treatment after 400 h isothermal oxidation reduces oxide content by ~80% and porosity by ~90%, effectively healing defects and suppressing bond-coat degradation. This post-processing step can extend coating service life by mitigating TGO growth and interfacial stress concentration. • • CMAS and molten-salt corrosion remain primary failure accelerators; Al2O3–TiO2 codoping and Sc2O3–Y2O3 co-stabilization improve resistance, but quantitative corrosion rates under combined CMAS/water-oxygen environments are lacking, necessitating standardized testing protocols. • • Multi-component and high-entropy rare-earth zirconates exhibit low thermal conductivity and enhanced phase stability, yet long-term cycling data beyond 500 h are scarce. Industrial adoption requires validated performance metrics and cost parity with conventional YSZ.