Novel Thermal Barrier Coatings with Phase Composite Structures for Extreme Environment Applications: Concept, Process, Evaluation and Performance

In this paper, a novel concept in the field of phase composite ceramics has been proposed and applied for creating topcoats durable thermal barrier coatings (TBCs), which is one most critical technologies advanced high-efficiency gas turbine engines extreme environments. The ceramic TBCs were designed to demonstrate superior comprehensive performance-related merits, benefits, advantages over conventional single-phase with topcoat 8YSZ or Gd2Zr2O7, including stability, shock durability, low conductivity, solid particle erosion resistance. we review summarize development work conducted so far related concept, processing, experimental investigation into TBC behaviors at elevated temperatures (typically, ≥1250 °C) using different evaluation characterization methods, isothermal sintering, burner rig test, particle-impinging CMAS corrosion test. Two-phase (t’+c) zirconia-based demonstrated improved resistance comparison (t’), TBC, Gd2Zr2O7 when used separately. Additionally, triple-phase (t’+c+YAG) sample TBC’s damage modes failure mechanisms cycling resistance, behavior, infiltration are also characterized discussed detail, terms microstructural performance evaluation.