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International Journal of Minerals,Metallurgy and Materials 2024年第5期31卷 1147-1165页

作者： Zijian Peng Yuhao Wang Shuqi Wang Junteng Yao Qingyuan Zhao Enyu Xie Guoliang Chen Zhigang Wang Zhanguo Liu Yaming Wang Jiahu Ouyang School of Materials Science and Engineering Harbin Institute of TechnologyHarbin 150001China School of Materials and Metallurgical Engineering Inner Mongolia University of Science&TechnologyBaotou 014010China

The A_(2)B_(2)O_(7)-type rare earth zirconate compounds have been considered as promising candidates for thermal barrier coating(TBC) materials because of their low sintering rate,improved phase stability,and reduced thermal conductivity in contrast with the currently used yttria-partially stabilized zirconia (YSZ) in high operating temperature environments.This review summarizes the recent progress on rare earth zirconates for TBCs that insulate high-temperature gas from hot-section components in gas turbines.Based on the first principles,molecular dynamics,and new data-driven calculation approaches,doping and high-entropy strategies have now been adopted in advanced TBC materials design.In this paper,the solid-state heat transfer mechanism of TBCs is explained from two aspects,including heat conduction over the full operating temperature range and thermal radiation at medium and high temperature.This paper also provides new insights into design considerations of adaptive TBC materials,and the challenges and potential breakthroughs are further highlighted for extreme environmental applications.Strategies for improving thermophysical performance are proposed in two approaches:defect engineering and material compositing.

关键词： rare earth zirconates thermal barrier coatings defect engineering doping and compositing thermal conductivity thermal expansion

Surface roughness affects metastable non-wetting behavior of silicate melts on thermal barrier coatings

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Rare Metals 2022年第2期41卷 469-481页

作者： Shan-Jie Yang Wen-Jia Song Donald B.Dingwell Jian He Hong-Bo Guo School of Materials Science and Engineering Beihang UniversityBeijing 100191China Department of Earth and Environmental Sciences Ludwig-Maximilians-Universita¨t Mu¨nchenMunich 80333Germany Research Institute for Frontier Science Beihang UniversityBeijing 100191China

Airborne silicate pollutants in flight corridors pose a serious threat to aviation safety whose severity is directly linked to the wettability of molten silicates on thermal barrier coatings(TBCs)at high temperatures(1200–2000℃).Despite its importance,the wettability of silicate melt on TBCs has not been well investigated.In particular,the surface morphology characteristics of TBCs can be expected to have a first-order effect on the wettability of silicate melt on such TBCs.Here,a series of atmospheric plasma spray(APS)yttria-stabilized zirconia(YSZ)TBCs with varying surface roughness were generated through the application of mechanical polishing.The metastable nonwetting behavior of three representative types of airborne silicate ash(volcanic ash,fly ash and a synthetic calcium–magnesium–aluminum–silicates(CMAS)powder)on these TBCs with varying surface roughness was investigated.It was observed that the smoother the surface of TBCs was,the larger the contact angle was with the molten silicate melts,and consequently,the smaller the area of damage was on the TBCs.Thus,the reduction in TBCs surface roughness(here via mechanical polishing)led to an improvement in the wetting and spreading resistance of TBCs to silicate melts at high temperature.In support of these observations and conclusions,the surface morphology of the TBC(both before and after polishing)had been characterized,and the mechanism of the surface roughness-dependence of wettability had been discussed.These results should contribute to reducing the deposition rate of silicate melt on TBCs,thus extending the lifetime of turbine blades and reducing maintenance costs.

关键词： thermal barrier coatings Surface roughness Silicate melts Metastable wettability Calcium–magnesium–aluminum–silicates(CMAS)mitigation method

Premature failure induced by non-equilibrium grain-boundary tantalum segregation in air-plasma sprayed ZrO_(2)-YO_(1.5)-TaO_(2.5)thermal barrier coatings

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International Journal of Minerals,Metallurgy and Materials 2022年第12期29卷 2189-2200页

作者： Yao Yao Di Wu Xiaofeng Zhao Fan Yang Shanghai Key Laboratory of Advanced High Temperature Materials and Precision Forming Shanghai Jiao Tong UniversityShanghai 200240China School of Mechanical Engineering Shanghai Jiao Tong UniversityShanghai 200240China

ZrO_(2)-YO_(1.5)-TaO_(2.5)(ZYTO)is a promising top-coat material for thermal barrier coatings(TBCs).The bulk properties of ZYTO have been reported by several studies,but its performances as TBCs are less-well understood.In this work,ZYTO TBCs were prepared by air plasma spraying(APS)and their thermal cycling performances were investigated at 1150℃.Despite of the good bulk properties,APS ZYTO TBCs present an extremely short thermal fatigue life.This is attributed to the non-equilibrium grain-boundary segregation of TaO_(2.5) induced by limited solubility and rapid quenching during APS process,resulting in a tetragonal(t)to cubic(c)and metastable-tetragonal(tm)phase transformation in ZYTO TBCs.The volume shrinkage(~0.74vol%)of phase transformation leads to many cracks at the c/tm phase boundaries after deposition.On the other hand,the formation of cubic phase with massive grain-boundary Ta segregation induces a large intergranular embrittlement and a weak bonding strength(~5.3 MPa),resulting in the premature failure of the ZYTO TBCs.

关键词： thermal barrier coatings air plasma spray tantalum segregation phase transformation

thermal Analysis of Turbine Blades with thermal barrier coatings Using Virtual Wall Thickness Method

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Computer Modeling in Engineering & Sciences 2023年第2期134卷 1219-1236页

作者： Linchuan Liu Jian Wu Zhongwei Hu Xiaochao Jin Pin Lu Tao Zhang Xueling Fan Joint Research Center for Extreme Environment and Protection Technology School ofAerospace EngineeringXi’an Jiaotong UniversityXi’an710049China AEEC Sichuan Gas Turbine Establishment Chengdu610500China

Avirtual wall thicknessmethod is developed to simulate the temperature field of turbine bladeswith thermal barrier coatings(TBCs),to simplify the modeling process and improve the calculation efficiency.The results show that the virtualwall thickness method can improve themesh quality by 20%,reduce the number ofmeshes by 76.7%and save the calculation time by 35.5%,compared with the traditional real wall thickness method.The average calculation error of the two methods is between 0.21%and 0.93%.Furthermore,the temperature at the blade leading edge is the highest and the average temperature of the blade pressure surface is higher than that of the suction surface under a certain service condition.The blade surface temperature presents a high temperature at both ends and a low temperature in themiddle height when the temperature of incoming gas is uniformand constant.The thermal insulation effect of TBCs is the worst near the air film hole,and the best at the blade leading edge.According to the calculated temperature field of the substrate-coating system,the highest thermal insulation temperature of the TC layer is 172.01 K,and the thermal insulation proportions of TC,TGO and BC are 93.55%,1.54%and 4.91%,respectively.

关键词： Turbine blade thermal analysis thermal barrier coatings finite element method virtual wall thickness

Porous a-Al_2O_3 thermal barrier coatings with dispersed Pt particles prepared by cathode plasma electrolytic deposition

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International Journal of Minerals,Metallurgy and Materials 2016年第1期23卷 92-101页

作者： Peng Wang Ye-dong He Shun-jie Deng Jin Zhang Beijing Key Laboratory for Corrosion Erosion and Surface Technology University of Science and Technology Beijing

Porous α-Al2O3 thermal barrier coatings （TBCs） containing dispersed Pt particles were prepared by cathode plasma electrolytic deposition （CPED）. The influence of the Pt particles on the microstructure of the coatings and the CPED process were studied. The prepared coatings were mainly composed of α-Al2O3. The average thickness of the coatings was approximately 100 μm. Such single-layer TBCs ex- hibited not only excellent high-temperature cyclic oxidation and spallation resistance, but also good thermal insulation properties. Porous α-Al2O3 TBCs inhibit further oxidation of alloy substrates because of their extremely low oxygen diffusion rate, provide good thermal insu- lation because of their porous structure, and exhibit excellent mechanical properties because of the toughening effect of the Pt particles and because of stress relaxation induced by deformation of the porous structure.

关键词： porous material thermal barrier coatings alumina platinum electrolytic deposition oxidation

Hot Corrosion Behavior of Double-ceramic-layer LaTi_2 Al_(9)O_(19)/YSZ thermal barrier coatings

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Chinese Journal of Aeronautics 2012年第1期25卷 137-142页

作者： XIE Xiaoyun GUO Hongbo GONG Shengkai XU Huibin School of Materials Science and Engineering Key Laboratory of Aerospace Materials&Performance(Ministry of Education)Beihang UniversityBeijing 100191China

LaTi2Al9O19 （LTA） exhibits promising potential as a new kind of thermal barrier coating （TBC） material, due to its excellent high-temperature capability and low thermal conductivity. In this paper, LTA/yttria stabilized zirconia （YSZ） TBCs are produced by atmospheric plasma spraying. Hot corrosion behavior and the related failure mechanism of the coating are investigated. Decomposition of LTA does not occur even after 1 458 hot corrosion cycles at 1 373 K, revealing good chemical stability in molten salt of Na=SO4 and NaCl. However, the molten salt infiltrates to the bond coat, causing dissolving of the thermally grown oxide （TGO） in the molten salt and hot corrosion of the bond coat. As a result, cracking of the TBC occurs within the oxide layer. In conclusion, the ceramic materials LTA and YSZ reveal good chemical stability in molten salts of Na2SO4 and NaCl, and the bond coat plays a significant role in providing protection for the component against hot corrosion in the LTA/YSZ TBCs. LTA exhibits very promising potential as a novel TBC material.

关键词： thermal barrier coatings LaTi2Al9O19 hot corrosion plasma spraying failure

Effect of Bionic Unit Shapes on Solid Particle Erosion Resistance of ZrO2-7wt%Y2O3 thermal barrier coatings Processed by Laser

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Journal of Bionic Engineering 2018年第3期15卷 545-557页

作者： Panpan Zhang Fuhai Li Xiaofeng Zhang Zhihui Zhang Chaolin Tan Luquan Ren Yueliang Wang Wenyou Ma Min Liu The Key Laboratory of Bionic Engineering (Ministry of Education China) Jilin University 5988 Renmin Street Changchun 130022 China Guangdong Institute of New Materials National Engineering Laboratory for Modern Materials Surface Engineering Technology the Key Lab of Guangdong for Modern Surface Engineering Technology Guangzhou 510651 China The State Key Laboratory of Automotive Simulation and Control Jilin University 5988 Renmin Street Changchun 130022 China

Inspired by the coupling phenomena in biological systems, to improve the solid particle erosion resistance of thermal barrier coatings （TBCs）, different kinds of bionic units were made on the coating surfaces using Bionic Coupled Laser Remelting （BCLR） process. The NiCoCrAlYTa/ZrO2-7wt%Y2O3 double-layer structured TBCs were prepared by air plasma spraying. The microstructure, microhardness and phase composition of the as-sprayed and bionic specimens were examined. The solid particle erosion behaviors of bionic specimens as function of bionic unit shape were investigated. The results indicated that the bionic specimens had better erosion resistance than the as-sprayed specimen. The specimen with striation and grid bionic units had the better erosion resistance, while the dot showed the worse. The bionic units were characterized by the dense columnar crystal structure and the high hardness, which are the main reasons for improving the erosion resistance. Under the synergistic action of the shear stress and normal stress on the protrusive coating surface, the erosion failure of the as-sprayed TBCs was proved to be the fracture and spallation of the splats. By contrast, the spallation of segmented bionic unit occurred in the overlapping area between the adjacent laser irradiation, and the erosive unit surface presented the clear and deep furrows, which revealed that the erosion failure mechanism of bionic TBCs was dominated by brittle and some ductile erosion. These results showed more opportunities for bionic application in improving the solid particle erosion resistance of components in the windy and sandy environment.

关键词： bionic thermal barrier coatings erosion resistance laser

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

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Journal of Materials Science & Technology 2019年第12期35卷 2814-2823页

作者： Qiaomu Liu Shunzhou Huang Aijie He AECC Sichuan Gas Turbine Establishment

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.

关键词： Composite ceramics thermal barrier coatings Aero-engine Yttria stabilized zirconia Phase stability thermal conductivity Failure mechanism

Plasma spray-physical vapor deposition toward advanced thermal barrier coatings:a review

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Rare Metals 2020年第5期39卷 479-497页

作者： Mei-Jun Liu Gao Zhang Yan-Hong Lu Jia-Qi Han Guang-Rong Li Cheng-Xin Li Chang-Jiu Li Guan-Jun Yang State Key Laboratory for Mechanical Behavior of Materials School of Materials Science and EngineeringXi’an Jiaotong UniversityXi'an 710049China

Plasma spray–physical vapor deposition(PS–PVD)is a unique technology that enables highly tailorable functional films and coatings with various rare metal elements to be processed.This technology bridges the gap between conventional thermal spray and vapor deposition and provides a variety of coating microstructures composed of vapor,liquid,and solid deposition units.The PS–PVD technique serves a broad range of applications in the fields of thermal barrier coatings(TBCs),environmental barrier coatings(EBCs),oxygen permeable films,and electrode films.It also represents the development direction of high-performance TBC/EBC preparation technologies.With the PS–PVD technique,the composition of the deposition unit determines the microstructure of the coating and its performance.When coating materials are injected into a nozzle and transported into the plasma jet,the deposition unit generated by a coating material is affected by the plasma jet characteristics.However,there is no direct in situ measurement method of material transfer and deposition processes in the PS–PVD plasma jet,because of the extreme conditions of PS–PVD such as a low operating pressure of*100 Pa,temperatures of thousands of degrees,and a thin and high-velocity jet.Despite the difficulties,the transport and transformation behaviors of the deposition units were also researched by optical emission spectroscopy,observation of the coating microstructure and other methods.This paper reviews the progress of PS–PVD technologies considering the preparation of advanced thermal barrier coatings from the perspective of the transport and transformation behaviors of the deposition units.The development prospects of new high-performance TBCs using the PS–PVD technique are also discussed.

关键词： Plasma spray–physical vapor deposition (PSPVD) Deposition unit Cross-domain behavior Deposition mechanism thermal barrier coatings (TBCs)

Reliability assessment on interfacial failure of thermal barrier coatings

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Acta Mechanica Sinica 2016年第5期32卷 915-924页

作者： Jin-Wei Guo Li Yang Yi-Chun Zhou Li-Min He Wang Zhu Can-Ying Cai Chun-Sheng Lu Key Laboratory of Key Film Materials & Application for Equipment (Hunan Province) School of Materials Science and Engineering Xiangtan UniversityXiangtan 411105China Key Laboratory of Low Dimensional Materials & Application Technology (Ministry of Education) School of Materials Science and Engineering Xiangtan UniversityXiangtan 411105China Beijing Institute of Aeronautical Materials Beijing 100095China Department of Mechanical Engineering Curtin UniversityPerthWestern Australia 6845Australia

thermal barrier coatings（TBCs） usually exhibit an uncertain lifetime owing to their scattering mechanical properties and severe service conditions. To consider these uncertainties, a reliability assessment method is proposed based on failure probability analysis. First, a limit state equation is established to demarcate the boundary between failure and safe regions, and then the failure probability is calculated by the integration of a probability density function in the failure area according to the first- or second-order moment.It is shown that the parameters related to interfacial failure follow a Weibull distribution in two types of TBC. The interfacial failure of TBCs is significantly affected by the thermal mismatch of material properties and the temperature drop in service.

关键词： Reliability assessment thermal barrier coatings Interfacial failure