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Thermal barrier coatings

Edited by H Xu, Beijing University of Aeronautics and Astronautics (BUAA) and H Guo, Beihang University, China

Woodhead Publishing Series in Metals and Surface Engineering No. 39

Provides a comprehensive review of this important subject.
Materials World

 - reviews the latest advances in processing and performance of thermal barrier coatings, as well as their failure mechanisms
 - explores the materials and structures of thermal barrier coatings incorporating cover both metallic and ceramic coating materials as well as nanostructured coating
 - assesses established and advanced processing and spraying techniques, including plasma vapour deposition and detonation gun spraying
 - discusses the performance and failure of thermal barrier coatings, including oxidation and hot-corrosion, non-destructive evaluation and new materials, technologies and processes

Effective coatings are essential to counteract the effects of corrosion and degradation of exposed materials in high-temperature environments such as gas turbine engines. Thermal barrier coatings reviews the latest advances in processing and performance of thermal barrier coatings, as well as their failure mechanisms.

Part one reviews the materials and structures of thermal barrier coatings. Chapters cover both metallic and ceramic coating materials as well as nanostructured coatings. Part two covers established and advanced processing and spraying techniques, with chapters on the latest advances in plasma spraying and plasma vapour deposition as well as detonation gun spraying. Part three discusses the performance and failure of thermal barrier coatings, including oxidation and hot-corrosion, non-destructive evaluation and new materials, technologies and processes.

With its distinguished editors and international team of contributors, Thermal barrier coatings is an essential reference for professional engineers in such industries as energy production, aerospace and chemical engineering as well as academic researchers in materials.

ISBN 1 84569 658 1
ISBN-13: 978 1 84569 658 0
January 2011
360 pages  234 x 156mm  hardback  
£135.00 / US$230.00 / €160.00

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About the editors

Dr Huibin Xu is a Professor and Dr Hongbo Guo is an Associate Professor in the School of Material Science and Engineering at Beihang University (formerly Beijing University of Aeronautics), China. Both are noted for their research on high-temperature corrosion and coating technology.

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Contents

PART 1 MATERIALS AND STRUCTURE
PART 2 PROCESSING AND SPRAYING TECHNIQUES
PART 3 PERFORMANCE OF THERMAL BARRIER COATINGS

PART 1 MATERIALS AND STRUCTURE

Thermal barrier coatings prepared by electron beam physical vapor deposition (EB-PVD)
D Zhang, North China Electric Power University, China
 - Introduction
 - Preparation process and parameters
 - Preparation process of two-layered thermal barrier coatings (TBCs)
 - Factors affecting thermal cyclic behaviour of TBCs
 - Preparation of gradient thermal barrier coatings (GTBCs)
 - Failure mechanism
 - Conclusion
 - References

Ceramic thermal barrier coating materials
W Ma and H Dong, Inner Mongolia University of Technology, China
 - Introduction
 - State-of-the-art ceramic thermal barrier coating (TBC) material – yttria stabilized zirconia (YSZ)
 - Zirconia doped with one or more oxides
 - Yttria stabilized hafnia and other alternative ceramic TBC materials
 - Lanthanum compounds, silicates and rare earth oxides
 - (Ca1-xMgx)Zr4(PO4)6 (CMZP), perovskite oxides and metal-glass composite
 - Future trends
 - References

Metallic coatings for high-temperature oxidation resistance
X Peng, Chinese Academy of Sciences, China
 - Introduction
 - Oxidation-resistant metallic coatings and their fabrication techniques
 - Metallic coatings as bond coats for thermal barrier coatings (TBCs)
 - Conclusions
 - Acknowledgements
 - References

Nanostructured thermal barrier coatings
C Zhou and Q Yu, Beihang University, China
 - Introduction
 - Spray drying process making powders
 - Phase composition and microstructure of nanostructured thermal barrier coatings (TBCs)
 - Mechanical properties
 - Thermophysical properties and failure behaviour
 - Conclusion
 - References

PART 2 PROCESSING AND SPRAYING TECHNIQUES

Plasma spraying and its applications: processes and applications
J Xu and K A Khor, Nanyang Technological University, Singapore
 - Introduction
 - Basic plasma concepts
 - Plasma spraying
 - Applications of plasma spraying
 - Conclusions
 - Acknowledgements
 - References

Processing, microstructures and properties of thermal barrier coatings by electron beam physical vapor deposition (EB-PVD)
S Gong and Q Wu, Beihang University, China
 - Introduction
 - Description of the physical principles of electron beam physical vapor deposition (EB-PVD)
 - Manufacturing of thermal barrier coatings (TBCs) by EB-PVD
 - EB-PVD TBC microstructure and its advantages over plasma-sprayed coatings
 - Hot-fatigue behavior and failure mechanisms of TBCs
 - References

Processing, microstructures and properties of thermal barrier coatings by plasma spraying (PS)
L Chen, China University of Petroleum, China
 - Introduction
 - Processing of thermal barrier coatings (TBCs) by plasma spraying (PS)
 - Microstructures of TBCs processed by PS
 - Properties of TBCs processed by PS
 - Conclusion
 - References

Plasma-sprayed thermal barrier coatings with segmentation cracks
H Guo, R Yao and L Zhou, Beihang University, China
 - Introduction
 - Manufacturing of segmented thermal barrier coatings (TBCs)
 - Microstructure of segmented TBCs
 - Thermophysical and mechanical properties of segmented TBCs
 - Thermal shock resistance and associate failure mechanism
 - Future trends
 - References

Detonation gun sprayed thermal barrier coatings
P L Ke, Y N Wu and C Sun, Chinese Academy of Sciences, P. R. China
 - Introduction
 - Detonation gun (D-gun) sprayed thermal barrier coatings (TBCs)
 - TBCs deposited through arc ion plating (AIP)/D-gun two-step technology
 - Future trends
 - Conclusion
 - References

PART 3 PERFORMANCE OF THERMAL BARRIER COATINGS

Oxidation and hot-corrosion of thermal barrier coatings (TBCs)
C Zhou and Y Song, Beihang University, China
 - Introduction
 - Oxidation of thermal barrier coatings
 - Failure mechanisms of TBCs
 - The degradation mechanisms experienced by TBC systems exposed to deposits
 - Conclusions
 - References

Failure mechanism of thermal barrier coatings by electron beam physical vapor deposition (EB-PVD) under thermo-mechanical coupled loads
C Zhang, Baosteel Group Corporation and C Chen, AVIC Commercial Aircraft Engine Co., Ltd, China
 - Introduction
 - Establishment of gas turbine service environment simulation system
 - Failure mechanism of electron beam physical vapor deposited thermal barrier coatings (EB-PVD TBC) under in-plane thermal gradient coupled with mechanical loading
 - Failure mechanism of EB-PVD TBC under 3-D thermal gradient coupled with mechanical loading
 - Conclusions
 - References

Non-destructive evaluation (NDE) of thermal barrier coatings
G Chen, Northwestern Polytechnical University, China
 - Introduction
 - Failure of thermal barrier coatings (TBCs)
 - Development of failure inspection methods
 - Future trends
 - Reference

Substrate and bond coat related failure of thermal barrier coatings
R Wu, National Institute for Materials Science (NIMS), Japan
 - Introduction
 - Substrate related failure of thermal barrier coatings (TBCs)
 - Compatibility issues of nickel-based single crystal superalloys with thermal barrier coating systems
 - Bond coat related failure of TBCs
 - Effect of bond coat on the TBC degradation mechanisms
 - Conclusions and future trends
 - References

Life prediction of thermal barrier coatings
H Y Qi and X G Yang, Beihang University, China
 - Introduction
 - The mechanical behavior of thermal barrier coating (TBC) systems under evaluated temperatures
 - Life prediction for TBCs
 - Future trends
 - Conclusion
 - References

New materials, technologies and processes in thermal barrier coatings
H Xu and J Wu, Beihang University, China
 - Introduction
 - Chemically modified yttria stabilized zirconia (YSZ)
 - Alternative low thermal conductivity (κ) materials
 - Microstructure modification
 - Advanced processing technologies
 - Future trends
 - References