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Processing science of advanced thermal-barrier systems

MRS Bulletin volume 37, pages 903–910 (2012)Cite this article

Abstract

Thermal-barrier coatings (TBCs) are complex, defected, thick films made of zirconia-based refractory ceramic oxides. Their widespread applicability has necessitated development of high throughput, low cost materials manufacturing technologies. Thermal plasmas and electron beams have been the primary energy sources for processing of such systems. Electron-beam physical vapor deposition (EBPVD) is a sophisticated TBC fabrication technology for rotating parts of aero engine components, while atmospheric plasma sprays (APS) span the range from rotating blades of large power generation turbines to afterburners in supersonic propulsion engines. This article presents a scientific description of both contemporary manufacturing processes (EBPVD, APS) and emerging TBC deposition technologies based on novel extensions to plasma technology (suspension spray, plasma spray-PVD) to facilitate novel compliant and low thermal conductivity coating architectures. TBCs are of vital importance to both performance and energy efficiency of modern turbines with concomitant needs in process control for both advanced design and reliable manufacturing.

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Acknowledgments

We are grateful to Dr. Gopal Dwivedi of Stony Brook University for his assistance in integrating the figures for this article.

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Authors and Affiliations

  1. Center for Thermal Spray Research, Department of Materials Science and Engineering, Stony Brook University, USA

    Sanjay Sampath

  2. German Aerospace Center, Institute of Materials Research, Germany

    Uwe Schulz

  3. Institute of Energy and Climate Research (IEK-1), Forschungszentrum Jülich GmbH, Germany

    Maria Ophelia Jarligo

  4. National Institute for Materials Science, Japan

    Seiji Kuroda

Authors
  1. Sanjay Sampath
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  2. Uwe Schulz
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  3. Maria Ophelia Jarligo
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  4. Seiji Kuroda
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Correspondence to Sanjay Sampath.

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Sampath, S., Schulz, U., Jarligo, M.O. et al. Processing science of advanced thermal-barrier systems. MRS Bulletin 37, 903–910 (2012). https://doi.org/10.1557/mrs.2012.233

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  • DOI: https://doi.org/10.1557/mrs.2012.233