Sintering Modeling of Thermal Barrier Coatings at Elevated Temperatures: A Review of Recent Advances

Abstract

To achieve a higher efficiency in gas turbine engine by increasing the inlet-temperature of burning gas is one of the primary goals in aviation industry. The development of thermal barrier coating system (TBCs) continuously raises the inlet-temperature of gas turbine engine in the past decades. Due to the complexity of TBCs and harsh operation environments, the degradation and failure mechanisms of hot section components have not been fully understood, and consequently limits the application of TBCs. It was identified that high-temperature sintering of the topcoat in a typical TBC could be one of the major sources of its failure since the microstructures of the constituent coating layers evolve dynamically during the service period, resulting in significant changes of mechanical and thermal physical properties of the coating system. This paper intends to review recent advances of analytical and numerical modeling of sintering of topcoat in TBCs including the modeling methodology and applications of the models, particularly the implementation of finite element combined with specific materials constitutive functions. Critical remarks on the future development and applications of these models are also discussed in the end.

Progress update on extending the durability of air plasma sprayed thermal barrier coatings

“…Sintering-related performance degradation is a primary source of concern for TBC durability. The problem is worsening as turbine entrance temperatures continue to rise [19][20][21]. Sintering and densification of the YSZ topcoat occur at temperatures as low as 1000 °C and become apparent at temperatures beyond 1200 °C [22,23].…”

Near‐Infrared Trapping by Surface Plasmons in Randomized Platinum–Ceramic Metamaterial for Thermal Barrier Coatings

“…[ 7 ] In addition, such cracks and micropores could shrink or even diminish due to the sintering effect at high temperature and weaken the strength. [ 8 ] Multilayer structure with alternating compositions with different refractive indexes (such as YSZ and Al 2 O 3 ) was exploited to increase scattering and thus to enhance reflectivity. [ 9,10 ] In addition to the complex processing and limited bandwidth of the reflected radiation, the reflection of the multilayers also requires stringent layers which inevitably deteriorate due to interfacial smearing under long‐term service at high temperature.…”

Polyacrylate Decorating Poly(ethylene terephthalate) (PET) Film Surface for Boosting Oxygen Barrier Property

“…The former includes polyvinyl alcohol (PVA) [36] and polyvinylidene chloride (PVDC) [37]. The other one is an amorphous polymer coating with a cross-linking structure and entangled network [38]. However, the development of crystalline polymers is impeded by several shortcomings during practical applications.…”