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New Materials for Thermal Barrier Coatings: Design, Manufacturing and Performance

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Ceramic Coatings for High-Temperature Environments

Part of the book series: Engineering Materials ((ENG.MAT.))

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Abstract

Ceramic thermal barrier coatings (TBCs) are aimed to protect the surface of metallic components of turbine engines exposed to extreme temperature as well as to environmental attack promoted by oxygen and molten deposits. Their application allows to extend component life and can improve thermal capability and efficiency of next-generation engines. TBC design includes detailed analysis of materials’ composition and TBC architecture. Basic requirements are demanded in terms of low thermal conductivity and high phase stability, whereas the porous and stress compliant microstructure should preserve high-temperature performance, since thermal cycling typically promotes partial sintering and thermal expansion mismatch between coating and substrate, thus assisting typical detrimental effects such as cracking, delamination and spallation. Yttria stabilized zirconia is the most common ceramic for industrial TBC manufacturing, under a large variety of operating environments. During the last decades, many ceramic oxides with potential enhanced properties were investigated and fabricated TBCs were tested at laboratory scale. However, prolonged high-temperature service requires further validation steps to successfully apply novel systems in real engines. This chapter explores state-of-the-art and recent developments in the matter of TBCs, focusing on the properties of novel compositions and TBC architectures, taking in account the main mechanisms inducing their in-service failure.

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Abbreviations

3D:

3 Dimension

APS:

Air Plasma Spraying

CMAS:

Calcium Magnesium Aluminum Silicate

CTE:

Coefficient of Thermal Expansion

CYSZ:

Ceria Yttria co-Stabilized Zirconia

DED:

Direct Energy Deposition

DySZ:

Dysprosia Stabilized Zirconia

EB-PVD:

Electron Beam Physical Vapor Deposition

FGM:

Functionally Graded Material

GZ:

Gadolinium Zirconate

NdCSZ:

Neodymia Ceria Stabilized Zirconia

LaYSZ:

Lanthana Yttria Stabilized Zirconia

LC:

Lanthanum Cerate

LPPS:

Low Pressure Plasma Spraying

LZ:

Lanthanum Zirconate

PECs:

Pockets of energy concentration

PS-PVD:

Plasma Spraying Physical Vapor Deposition

ScYSZ:

Scandia Yttria Stabilized Zirconia

SPS:

Suspension Plasma Spraying

SPPS:

Solution Precursor Plasma Spraying

SZ:

Samarium Zirconate

TBC:

Thermal Barrier Coating

TGO:

Thermally Grown Oxide

YSZ:

Yttria Stabilized Zirconia

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  1. Territorial and Production Systems Sustainability Department, ENEA, Palermo, Italy

    Giovanni Di Girolamo

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  1. FunGlass—Centre for Functional and Surface Functionalized Glass, Alexander Dubček University of Trenčín, Trenčín, Slovakia

    Amirhossein Pakseresht

  2. FunGlass—Centre for Functional and Surface Functionalized Glass, Alexander Dubček University of Trenčín, Trenčín, Slovakia

    Kamalan Kirubaharan Amirtharaj Mosas

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Di Girolamo, G. (2024). New Materials for Thermal Barrier Coatings: Design, Manufacturing and Performance. In: Pakseresht, A., Amirtharaj Mosas, K.K. (eds) Ceramic Coatings for High-Temperature Environments. Engineering Materials. Springer, Cham. https://doi.org/10.1007/978-3-031-40809-0_1

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