Thermal Barrier Coatings for High-Temperature Performance of Nickel-Based Superalloys: A Synthetic Review
Source abstract
Abstract
With the rising demands of industry to increase the working temperature of gas turbine blades and internal combustion engines, thermal barrier coatings (TBC) were found to be an effective way to further enhance the lifetime of aero components through the improvement of mechanical properties and oxidation-resistance. Thus, this paper aims to review coating technologies with special emphasis on plasma-sprayed thermal barrier coatings (PS), and those produced by physical vapor deposition (PVD) and chemical vapor deposition (CVD) methods. Each technology was assessed in terms of its effectiveness to enhance the mechanical response and oxidation resistance of nickel-based parts working at high temperature. The effect of coating technology on mechanical strength, hardness, fatigue and creep of nickel alloys was discussed to reveal the potential candidates for future applications in aggressive environments.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: High-Temperature Coating Behaviors · High Entropy Alloys Studies · Advanced materials and composites
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Institute of Fundamental Technological Research, Polish Academy of Sciences, ul. Pawińskiego 5B, 02-106 Warsaw, Poland
Faculty of Mechanical and Industrial Engineering, Warsaw University of Technology, ul. Narbutta 85, 02-524 Warsaw, Poland
References (98)
Show source-provided references
1. Advanced materials and technologies for compressor blades of small turbofan engines10.1088/1757-899X/1024/1/012061 ↗
2. Development and analysis of thermal barrier coatings on gas turbine blades—A Review10.1016/j.matpr.2018.01.060 ↗
3. Thermal degradation of turbine components in a military turbofan10.1016/j.engfailanal.2022.106088 ↗
4. Blade Vibration Monitoring in a Low-Pressure Steam Turbine10.1115/GT2018-76657 ↗
5. Thermal barrier coatings for high temperature applications—A short review10.1016/j.matpr.2020.08.017 ↗
6. Murshed, S.M.S., and Lopes, M.M. (2017). Heat Exchangers, IntechOpen.
7. Al2O3-modified PS-PVD 7YSZ thermal barrier coatings for advanced gas-turbine engines10.1038/s41529-020-00134-5 ↗
8. Szczepankowski, A., Przysowa, R., Perczynski, J., and Kułaszka, A. (2022). Health and Durability of Protective and Thermal Barrier Coatings Monitored in Service by Visual Inspection. Coatings, 12.10.3390/coatings12050624 ↗
9. Thermal barrier coatings: Characteristics of microstructure and properties, generation and directions of development of bond
10. Bonaquist, D., Feuerstein, A., Buchakjian, L., and Brooks, P. (2017). The Role of Thermal Barrier Coating in Maximizing Gas Turbine Engine Efciency and Lowering CO2 Emissions, Praxair Techology, Inc.
11. Ceramic Top coats of Plasma-Sprayed Thermal Barrier Coatings: Materials, Processes, and Properties10.1007/s11666-017-0597-7 ↗
12. Microstructure assessment at high temperature in NiCoCrAlY overlay coating obtained by laser metal deposition10.1016/j.jmrt.2018.12.006 ↗
13. YSZ/NiCrAlY interface oxidation of APS thermal barrier coatings10.1016/j.corsci.2018.06.035 ↗
14. Improvement of thermally grown oxide layer in thermal barrier coating systems with nano alumina as third layer10.1016/S1003-6326(13)62600-X ↗
15. Advanced intermetallic iron aluminide coatings for high temperature applications10.1016/j.pmatsci.2020.100769 ↗
16. The Effect of Hot Treatment on Composition and Microstructure of HVOF Iron Aluminide Coatings in Na2SO4 Molten Salts10.1007/s11666-019-00886-w ↗
17. Senderowski, C., Panas, A.J., Fikus, B., Zasada, D., Kopec, M., and Korytchenko, K.V. (2021). Effects of Heat and Momentum Gain Differentiation during Gas Detonation Spraying of FeAl Powder Particles into the Water. Materials, 14.10.3390/ma14237443 ↗
18. Thermophysical properties of multiphase Fe-Al intermetallic-oxide ceramic coatings deposited by gas detonation spraying10.1016/j.tca.2019.04.009 ↗
19. Structure Morphology of Fe-Al Coating Detonation Sprayed onto Carbon Steel Substrate
20. Detonation Deposited Fe-Al Coatings Part II: Transmission Electron Microscopy of Interlayers and Fe-Al Intermetallic Coating Detonation Sprayed onto the 045 Steel Substrate10.2478/v10172-011-0008-x ↗
21. Senderowski, C., Vigilianska, N., Burlachenko, O., Grishchenko, O., Murashov, A., and Stepanyuk, S. (2023). Effect of APS Spraying Parameters on the Microstructure Formation of Fe3Al Intermetallics Coatings Using Mechanochemically Synthesized Nanocrystalline Fe-Al Powders. Materials, 16.10.3390/ma16041669 ↗
22. Lencová, K., Frank Netrvalová, M., Vostřák, M., Lukáč, F., Mušálek, R., Česánek, Z., and Houdková, Š. (2023). Hot Corrosion Behavior of TWAS and HVOF NiCr-Based Coatings in Molten Salt. Materials, 16.10.3390/ma16041712 ↗
23. Bernecki, T.F. (1991). Thermal Spray Coatings: Properties, Processes and Applications, ASM International.
24. Natesan, K., Ganesan, P., and Lai, G. (1995, January 11–14). High temperature alloys and thermal spray coatings for energy conversion. Proceedings of the 2nd International Conference on Heat Resistant Materials, Gatlinburg, TN, USA.
25. Gas detonation spray forming of Fe–Al coatings in the presence of interlayer10.1016/j.surfcoat.2007.12.029 ↗
26. Columnar Thermal Barrier Coatings Produced by Different Thermal Spray Processes10.1007/s11666-021-01228-5 ↗
27. Technical and Economical Aspects of Current Thermal Barrier Coating Systems for Gas Turbine Engines by Thermal Spray and EBPVD: A Review10.1007/s11666-007-9148-y ↗
28. Ruys, A.J. (2021). Metal-Reinforced Ceramics, Woodhead Publishing.10.1016/B978-0-08-102869-8.00002-1 ↗
29. Williams, R. (2011). Surface Modification of Biomaterials, Woodhead Publishing.10.1533/9780857090768 ↗
30. Ambrosio, L. (2010). Biomedical Composites, Woodhead Publishing. [2nd ed.].10.1533/9781845697372 ↗
31. The Solution Precursor Plasma Spray (SPPS) Process: A Review with Energy Considerations10.1007/s11666-015-0272-9 ↗
32. Plasma-Sprayed Thermal Barrier Coatings: New Materials, Processing Issues, and Solutions10.1007/s11666-013-9889-8 ↗
33. Joseph, K., Oksman, K., George, G., Wilson, R., and Appukuttan, S. (2021). Fiber Reinforced Composites, Woodhead Publishing.
34. Guillon, O. (2020). Advanced Ceramics for Energy Conversion and Storage, Elsevier.
35. Modeling of Dynamics and Thermal History of Fe40Al Intermetallic Powder Particles Under Gas Detonation Spraying Using Propane-Air Mixture10.1007/s11666-019-00836-6 ↗
36. Analysis of gas flow evolution and shock wave decay in detonation thermal spraying systems10.1361/10599630419409 ↗
37. Tribological wear of Fe-Al coatings applied by gas detonation spraying
38. Controlling the properties of detonation-sprayed coatings: Major aspects10.1007/s11106-008-0011-6 ↗
39. El-Eskandarany, M.S. (2020). Mechanical Alloying, William Andrew Publishing. [3rd ed.].
40. Raza, A., Ahmad, F., Badri, T.M., Raza, M.R., and Malik, K. (2022). An Influence of Oxygen Flow Rate and Spray Distance on the Porosity of HVOF Coating and Its Effects on Corrosion—A Review. Materials, 15.10.3390/ma15186329 ↗
41. Weman, K. (2012). Welding Processes Handbook, Woodhead Publishing. [2nd ed.].10.1533/9780857095183.13 ↗
42. El-Eskandarany, M.S. (2015). Mechanical Alloying, William Andrew Publishing. [2nd ed.].
43. Chatti, S., Laperrière, L., Reinhart, G., and Tolio, T. (2019). CIRP Encyclopedia of Production Engineering, Springer.10.1007/978-3-662-53120-4 ↗
44. Thin-film coating; historical evolution, conventional deposition technologies, stress-state micro/nano-level measurement/models and prospects projection: A critical review10.1088/2053-1591/ab52cd ↗
45. Qiu, S.-Y., Wu, C.-W., Huang, C.-G., Ma, Y., and Guo, H.-B. (2021). Microstructure Dependence of Effective Thermal Conductivity of EB-PVD TBCs. Materials, 14.10.3390/ma14081838 ↗
46. A review on failure mechanism of thermal barrier coatings and strategies to extend their lifetime10.1016/j.ceramint.2019.12.200 ↗
47. Dincer, I., Colpan, C.O., and Kizilkan, O. (2018). Energetic and Environmental Dimensions, Academic Press.
48. LZC/YSZ DCL TBCs by EB-PVD: Microstructure, low thermal conductivity and high thermal cycling life10.1016/j.jeurceramsoc.2018.12.031 ↗
49. Thermal insulation properties of YSZ coatings: Suspension Plasma Spraying (SPS) versus Electron Beam Physical Vapor Deposition (EB-PVD) and Atmospheric Plasma Spraying (APS)10.1016/j.surfcoat.2016.06.010 ↗
50. Coating deposition regularity depended on orientation difference in PS-PVD plasma jet
51. Chemical Vapor Deposition and Atomic Layer Deposition of Coatings for Mechanical Applications10.1007/s11666-009-9364-8 ↗
52. Thin Film Deposition and Characterization Techniques
53. Coatings with Columnar Microstructures for Thermal Barrier Applications10.1002/adem.201900988 ↗
54. Plasma Spray-PVD: A New Thermal Spray Process to Deposit Out of the Vapor Phase10.1007/s11666-011-9654-9 ↗
55. Functional performance of Gd2Zr2O7/YSZ multi-layered thermal barrier coatings deposited by suspension plasma spray10.1016/j.surfcoat.2016.12.062 ↗
56. Tailoring columnar microstructure of axial suspension plasma sprayed TBCs for superior thermal shock performance10.1016/j.matdes.2018.02.011 ↗
57. Kukla, D., Kopec, M., Wang, K., Senderowski, C., and Kowalewski, Z.L. (2021). Nondestructive Methodology for Identification of Local Discontinuities in Aluminide Layer-Coated MAR 247 during Its Fatigue Performance. Materials, 14.10.3390/ma14143824 ↗
58. The promoted formation of an α-Al2O3 scale on a nickel aluminide with surface Cr2O3 particles10.1016/j.corsci.2016.07.029 ↗
59. Effect of high temperature oxidation on Inconel 718 and Inconel 718/YSZ/Gd2Zr2O710.1088/2053-1591/ab26d8 ↗
60. Advanced MCrAlY alloys with doubled TBC lifetime10.1016/j.surfcoat.2022.128931 ↗
61. Thermal expansion of MCrAlY alloys10.1016/j.surfcoat.2003.05.001 ↗
62. Fabrication of oxide dispersion strengthened bond coats with low Al2O3 content10.1007/s11666-017-0550-9 ↗
63. Oxide dispersion strengthened bond coats with higher alumina content: Oxidation resistance and influence on thermal barrier coating lifetime10.1007/s11085-019-09931-z ↗
64. The Use of APS Thermal Barrier Coatings in Corrosive Environments10.1007/s11085-017-9728-2 ↗
65. Influence of Bondcoat Spray Process on Lifetime of Suspension Plasma-Sprayed Thermal Barrier Coatings10.1007/s11666-017-0672-0 ↗
66. Influence of Bond Coat Surface Roughness on the Structure of Axial Suspension Plasma Spray Thermal Barrier Coatings—Thermal and Lifetime Performance10.1016/j.surfcoat.2014.08.067 ↗
67. Effect of Suspension Plasma-Sprayed YSZ Columnar Microstructure and Bond Coat Surface Preparation on Thermal Barrier Coating Properties10.1007/s11666-017-0584-z ↗
68. Advanced Microscopic Study of Suspension Plasma-Sprayed Zirconia Coatings with Different Microstructures10.1007/s11666-015-0310-7 ↗
69. Effect of Particle Size Distribution on Isothermal Oxidation Characteristics of Plasma Sprayed CoNi- and CoCrAlY Coatings10.1007/s11666-007-9131-7 ↗
70. Thermal Barrier Coatings for Gas-Turbine Engine Application10.1126/science.1068609 ↗
71. Parchovianský, M., Parchovianská, I., Hanzel, O., Netriová, Z., and Pakseresht, A. (2022). Phase Evaluation, Mechanical Properties and Thermal Behavior of Hot-Pressed LC-YSZ Composites for TBC Applications. Materials, 15.10.3390/ma15082839 ↗
72. Influence of cracks in APS-TBCs on stress around TGO during thermal cycling: A numerical simulation study10.1016/j.surfcoat.2015.11.036 ↗
73. Thermal conductivity of dense and porous yttria-stabilized zirconia10.1023/A:1017970924312 ↗
74. Influence of porosity on hardness and Young’s modulus of nanoporous EB-PVD TBCs by nanoindentation10.1016/j.matlet.2005.06.014 ↗
75. Wee, S., Do, J., Kim, K., Lee, C., Seok, C., Choi, B.-G., Choi, Y., and Kim, W. (2020). Review on Mechanical Thermal Properties of Superalloys and Thermal Barrier Coating Used in Gas Turbines. Appl. Sci., 10.10.3390/app10165476 ↗
76. Fatigue Testing of TBC on Structural Steel by Cyclic Bending
77. Fatigue behavior of a thermal barrier coated superalloy at 800 °C10.1016/j.msea.2006.10.035 ↗
78. Characterization of rupture and fatigue resistance of TBC superalloy for combustion liners10.1016/j.msea.2005.05.099 ↗
79. Fatigue Behavior of Thermal Barrier Coated DD6 Single Crystal Superalloy at 900 °C10.1007/978-981-13-5944-6_34 ↗
80. Kopec, M., Kukla, D., Yuan, X., Rejmer, W., Kowalewski, Z.L., and Senderowski, C. (2021). Aluminide Thermal Barrier Coating for High Temperature Performance of MAR 247 Nickel Based Superalloy. Coatings, 11.10.3390/coatings11010048 ↗
81. In situ characterization of high temperature elastic modulus and fracture toughness in air plasma sprayed thermal barrier coatings under bending by using digital image correlation10.1016/j.ceramint.2020.04.158 ↗
82. Investigation on interfacial fracture toughness of plasma-sprayed TBCs using a three-point bending method10.1016/j.surfcoat.2018.08.070 ↗
83. Mechanisms controlling the durability of thermal barrier coatings10.1016/S0079-6425(00)00020-7 ↗
84. Measurements of elastic modulus and fracture toughness of an air plasma sprayed thermal barrier coating using micro-cantilever bending10.1016/j.surfcoat.2019.05.031 ↗
85. Relationship between the mechanical properties and structure of a suspension plasma-sprayed thermal barrier coating with columnar microstructure10.1016/j.surfcoat.2022.128430 ↗
86. Effect of heat treatment on deformation and mechanical properties of 8 mol% yttria-stabilized zirconia by Berkovich nanoindentation10.1016/j.apsusc.2015.02.108 ↗
87. Anisotropic Mechanical Properties of Plasma-Sprayed Thermal Barrier Coatings at High Temperature Determined by Ultrasonic Method10.1007/s11666-016-0378-8 ↗
88. Anisotropic elastic properties of thermal spray coatings determined via resonant ultrasound spectroscopy10.1016/j.actamat.2010.06.003 ↗
89. Development and Adhesion Strength of Plasma-Sprayed Thermal Barrier Coating on the Cast Iron Substrate
90. Kukla, D., Kopec, M., Kowalewski, Z.L., Politis, D.J., Jóźwiak, S., and Senderowski, C. (2020). Thermal Barrier Stability and Wear Behavior of CVD Deposited Aluminide Coatings for MAR 247 Nickel Superalloy. Materials, 13.10.3390/ma13173863 ↗
91. Low-pressure plasma-induced physical vapor deposition of advanced thermal barrier coatings: Microstructures, modelling and mechanisms10.1016/j.mtphys.2021.100481 ↗
92. Investigation on Hot Corrosion Behaviour of Inconel 625 and Incoloy 800H Superalloys with YSZ-Thermal Barrier Coating Under High-Temperature Environment for Bioreactor Applications10.1155/2022/5861391 ↗
93. Twin-Structured Yttria-Stabilized t’ Zirconia Coatings Deposited by Plasma Spray Physical Vapor Deposition: Microstructure and Mechanical Properties10.1111/j.1551-2916.2006.01445.x ↗
94. Effect of Aluminizing on the Fatigue and High-Temperature Corrosion Resistance of Inconel 740 Nickel Alloy10.1007/s11837-022-05662-w ↗
95. Recent advances in the thermal barrier coatings for extreme environments
96. (2022). Thermal Barrier Coatings Market Share, Size, Trends, Industry Analysis Report, Segment Forecast, 2022–2030, POLARIS. Available online: https://www.polarismarketresearch.com/industry-analysis/thermal-barrier-coatings-tbc-market.
97. (2023, April 13). Thermal Barrier Coatings Market—Growth, Trends, COVID-19 Impact, and Forecasts (2023–2028). Available online: https://www.researchandmarkets.com/reports/4897094/thermal-barrier-coatings-market-growth.
98. A Perspective on Thermally Sprayed Thermal Barrier Coatings: Current Status and Trends10.1007/s11666-022-01330-2 ↗