Key Takeaways & Executive Findings
- •• Double-layer TBCs, particularly YSZ-based systems, remain the industrial mainstream due to mature manufacturing and cost-effectiveness, but face limitations such as phase transformation at ultra-high temperatures and thermal expansion mismatch. • Multi-layer/composite TBCs using A2B2O7 pyrochlore ceramics exhibit superior high-temperature performance, including lower thermal conductivity, better phase stability, and enhanced CMAS corrosion resistance. • APS produces lamellar porous microstructures beneficial for strain tolerance, while EB-PVD yields columnar structures with superior erosion resistance; emerging techniques like PS-PVD, SPS, and HVOF offer further optimization. • Future development of TBCs should focus on novel materials, advanced structural designs, and hybrid processes to overcome existing bottlenecks and meet demands of extreme operating conditions.
Abstract
To address the severe challenges faced by high-temperature components in extreme environments, thermal barrier coating (TBC) technology has become a critical approach to enhance their operating temperature tolerance and extend service life. This paper systematically reviews the research progress on the structural design and common preparation technologies of thermal barrier coatings, focusing on the evolutionary logic and performance characteristics of double-layer and multi-layer structures. It specifically analyzes double-layer structures on nickel-based superalloys, steels, and aluminum alloys, as well as multi-layer structures, dual bond coat + ceramic layer structures, and bond coat + multi-layer ceramic structures obtained through different preparation techniques. The article also elaborates on the intrinsic correlation between the microstructure and coating performance of TBCs prepared by two mainstream techniques: atmospheric plasma spraying (APS) and electron beam physical vapor deposition (EB-PVD). Research indicates that double-layer structures have been widely applied due to their good comprehensive performance; while multi-layer/composite structures constructed with A2B2O7-type ceramic materials show more promising application prospects in terms of temperature resistance, thermal cycling life, and corrosion resistance. In response to the current bottlenecks in TBC technology development, this paper looks forward to key future directions for high-performance TBCs from multiple dimensions, including new material development, new process integration, and advanced structural design, providing a systematic theoretical basis and clear technical pathways for the development of TBCs under more demanding service conditions.
1. Introduction
High-temperature components in advanced gas turbines, aero-engines, and other power systems are subjected to extreme thermal and mechanical loads, leading to degradation and failure. To improve thermal efficiency and service life, thermal barrier coatings (TBCs) have been widely adopted. These coatings provide thermal insulation, oxidation resistance, and corrosion protection, thereby enabling higher operating temperatures and extended component durability.
This review systematically examines the structural design and preparation technologies of TBCs, with emphasis on double-layer and multi-layer architectures. It analyzes the performance characteristics and failure mechanisms of double-layer coatings on various substrates, and explores the potential of multi-layer composite structures incorporating A2B2O7-type ceramics. Furthermore, the relationship between processing techniques (APS and EB-PVD) and coating microstructure is discussed, along with emerging methods. The findings highlight the trade-offs between conventional YSZ coatings and advanced pyrochlore-based systems, and outline future research directions for high-performance TBCs.
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ZHOU Xinnuo, ZHANG Ping (2026). Research Progress on the Structural Design and Common Preparation Technologies of Thermal Barrier Coatings. SinoTechIntel Verified Research. https://doi.org/10.16490/j.cnki.issn.1001-3660.2026.12.001
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Frequently Asked Questions
What are the main types of thermal barrier coating structures?
The main types include double-layer structures (bond coat + ceramic top coat) and multi-layer structures such as dual bond coat + ceramic layer, bond coat + multi-layer ceramic, and multi-process coupled structures. Double-layer YSZ coatings are common, while multi-layer designs with A2B2O7 ceramics offer enhanced performance.
What are the advantages of APS and EB-PVD techniques for TBCs?
APS produces lamellar porous microstructures that provide good strain tolerance and thermal insulation, but with lower erosion resistance. EB-PVD yields columnar microstructures with superior erosion resistance and strain compliance, but at higher cost. The choice depends on application requirements.
Why are A2B2O7 pyrochlore ceramics considered promising for TBCs?
A2B2O7 ceramics exhibit lower thermal conductivity, better high-temperature phase stability, and improved resistance to sintering and CMAS corrosion compared to conventional YSZ. These properties make them suitable for advanced multi-layer TBCs to operate at higher temperatures.
What are the main failure mechanisms of thermal barrier coatings?
Primary failure mechanisms include thermal cycling fatigue, oxidation of the bond coat leading to TGO growth, thermal expansion mismatch, and CMAS corrosion. These can cause spallation and delamination of the coating.
What are the future directions for TBC development?
Future directions include developing new ceramic materials with lower thermal conductivity and higher stability, optimizing multi-layer structural designs, integrating advanced preparation techniques like PS-PVD and SPS, and improving coating durability under extreme conditions.
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