Composite ceramics thermal barrier coatings of yttria stabilized zirconia for aero-engines

doi:10.1016/j.jmst.2019.08.003

Abstract

Abstract:

Composite ceramics thermal barrier coatings (TBCs) are widely used in the aero-engines field due to their excellent thermal insulation, which improves the service life and durability of the inherent hot components. The most typical, successful and widely used TBCs material is yttria stabilized zirconia (YSZ). In this paper, fabrication methods, coating structures, materials, failure mechanism and major challenges of YSZ TBCs are introduced and reviewed. The research tendency is put forward as well. This review provides a good understanding of the YSZ TBCs and inspires researchers to discover versatile ideas to improve the TBCs systems.

Key words: Composite ceramics, Thermal barrier coatings, Aero-engine, Yttria stabilized zirconia, Phase stability, Thermal conductivity, Failure mechanism

Qiaomu Liu, Shunzhou Huang, Aijie He. Composite ceramics thermal barrier coatings of yttria stabilized zirconia for aero-engines[J]. J. Mater. Sci. Technol., 2019, 35(12): 2814-2823.

Figures/Tables 12

Fig. 1. A cross-sectional image of a TBC system on an aero-turbine blade [3].

Fig. 2. The cross-sectional morphology of the PS TBCs with segmentation crack structure [23].

Fig. 3. The cross-sectional morphology of EB-PVD YSZ TBCs [26].

Fig. 4. PS-PVD YSZ coatings with different microstructures (a) quasi-columnar coating, (b) lamellar coating, (c) hybrid coating [32].

Fig. 5. The coating failure caused by the cracking of the TGO film [70].

Fig. 6. A schematic illustration showing the cracking mechanism in the APS TBCs [71].

Fig. 7. Failed blade caused by the CMAS [78].

Table 1 Applications of TBCs on commercial aero-engine parts [85].

Bond coat	Topcoat	Example GE	Example PW
VPS MCrAlY	APS YSZ	CF6-50 Vane 2	V2500 Vane 1
APS MCrAlY (aluminized)	APS YSZ	CF6-80 Vane 2	not applied
aluminized	EB-PVD YSZ	CFM56-7 Vane 1	not applied
Pt-Al	EB-PVD YSZ	CF6-80 Blade 1	not applied
EB-PVD MCrAlY	EB-PVD YSZ	not applied	PW2000 Blade1

Fig. 8. (a) HPT stage 2nd vane with TBCs and (b) microstructure of the TBCs [85].

Fig. 9. (a) HPT stage 1st blade with TBCs and (b) microstructure of the TBCs [85].

Fig. 10. (a) TBCs coated on the combustor tile and (b) the edge morphology of the cooling hole with TBCs.

Fig. 11. (a) HPT vanes with TBCs and (b) morphology of the cooling holes with TBCs.

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