Thermal Barrier Coatings: Materials, Processes, Properties and Applications

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Ceramic Coatings and Engineering Technology".

Deadline for manuscript submissions: 30 July 2025 | Viewed by 327

Special Issue Editor


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Guest Editor
Oerlikon Metco (US) Inc., Westbury, NY, USA
Interests: high-temperature materials; thermal/environmental barrier coatings; abradable coatings; coating technology application in aerospace and industry gas turbine engines

Special Issue Information

Dear Colleagues,

Thermal Barrier Coatings (TBCs) are used extensively in the hot sections of both aerospace and industrial gas turbine engines. The TBC has enabled engines to operate at gas temperatures well above the melting temperature of the superalloy, thereby improving engine efficiency and performance. Higher operating temperatures for gas turbine engines are continuously sought after in order to further improve their efficiency. As engine inlet temperatures increase, the need for reliable coatings with improved properties is becoming increasingly critical to protecting the durability of superalloy components. A highly durable TBC system relies on advanced materials, coating microstructures, critical coating processes, as well as application equipment for a robust, high-quality coating deposition. This Special Issue invites original research studies on the latest TBC development regarding new innovations in materials, process technologies, characterization, performance, and industrial applications.

Topics of interest include, but are not limited to, the following:

  • Novel TBC materials, including novel bond coats, phase-stable and low thermal conductivity coatings, and coatings that resist CMAS deposits ingested into the engine;
  • Coating processes, including thermal spray, suspension/solution plasma spray, physical vapor deposition, and chemical vapor deposition;
  • Multilayer and multifunction coating architecture and microstructure design;
  • Testing, characterization, performance, failure analysis, and applications;
  • Advanced equipment for robust and cost-effective coating deposition.

Dr. Dianying Chen
Guest Editor

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Keywords

  • thermal barrier coatings
  • coating process
  • CMAS resistance
  • oxidation
  • failure analysis
  • gas turbine engines

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Published Papers (1 paper)

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Research

18 pages, 4144 KiB  
Article
Integrated Microstructural and Chemical Approach for Improving CMAS Resistance in Thermal and Environmental Barrier Coatings
by Andrew J. Wright, Clara Mock, Timothy Sharobem, Nickolas Sotiropoulos, Chris Dambra, Brian Keyes and Anindya Ghoshal
Coatings 2025, 15(6), 680; https://doi.org/10.3390/coatings15060680 - 5 Jun 2025
Abstract
This study provides an investigation into the influence of surface roughness, porosity, and chemistry on the wettability and infiltration behavior of calcia-magnesia-alumino-silicates (CMASs) in thermal and environmental barrier coatings (T/EBCs) used in high-temperature gas turbine engines. High-temperature contact angle measurements were performed at [...] Read more.
This study provides an investigation into the influence of surface roughness, porosity, and chemistry on the wettability and infiltration behavior of calcia-magnesia-alumino-silicates (CMASs) in thermal and environmental barrier coatings (T/EBCs) used in high-temperature gas turbine engines. High-temperature contact angle measurements were performed at 1260 °C on 7 wt.% yttria-stabilized zirconia (7YSZ) and yttrium ytterbium disilicate (YYbDS, (Y1/2Yb1/2)2Si2O7) to evaluate the interaction of CMASs with different surface finishes and coating microstructures. The findings demonstrate that porosity plays a dominant role in determining CMAS infiltration dynamics. In YYbDS, increasing porosity from 6.3% to 22.7% facilitated the formation of an apatite layer that limited CMAS penetration to approximately 2 µm. Surface roughness exhibited a subtler influence in that reducing Sa from 0.61 µm to 0.05 µm increased the change in the contact angle by ~2°, although its impact was found to be less significant compared to porosity and reactive chemistry. These results indicate that an integrated approach that optimizes porosity, chemistry, and surface morphology can significantly enhance CMAS resistance. The study emphasizes that leveraging both microstructural and chemical properties is critical to developing coatings capable of withstanding the harsh conditions encountered in aerospace environments. Full article
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