Research Progress on the Structural Design and Common Preparation Technologies of Thermal Barrier Coatings

• 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.