热障涂层的结构设计及常用制备技术研究进展

周心诺; 张平

doi:10.16490/j.cnki.issn.1001-3660.2026.12.001

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表面技术 ›› 2026, Vol. 55 ›› Issue (12) : 1-18. DOI: 10.16490/j.cnki.issn.1001-3660.2026.12.001

腐蚀与防护

热障涂层的结构设计及常用制备技术研究进展

周心诺, 张平^*

作者信息 +

Research Progress on the Structural Design and Common Preparation Technologies of Thermal Barrier Coatings

ZHOU Xinnuo, ZHANG Ping^*

Author information +

文章历史 +

摘要

为应对高温部件在极端环境下所面临的严峻挑战,热障涂层技术已成为提升其工作温度、延长服役寿命的关键手段。本文系统综述了热障涂层的结构设计及常用制备技术的研究进展,重点分析了双层结构与多层结构的演化逻辑及其性能特征,具体包括镍基合金、钢基体及铝合金基体上的双层结构,以及结合不同制备技术获得的多层结构、双黏结层+陶瓷层结构、黏结层+多层陶瓷层结构等。文章也阐述了目前主流的两种热障涂层制备技术（大气等离子喷涂与电子束物理气相沉积技术）制备的热障涂层的微观结构和涂层性能之间的内在关联。研究表明,双层结构因具有良好的综合性能已获得广泛应用;而通过A₂B₂O₇型陶瓷材料构建的多层/复合结构,在耐温性能、热循环寿命及抗腐蚀性能方面展现出更具潜力的应用前景。针对当前热障涂层技术发展所面临的瓶颈,从新材料开发、新工艺融合及先进结构设计等多个维度,展望了未来高性能热障涂层的关键发展方向,为面向更严苛工况的热障涂层研发提供了系统的理论依据与清晰的技术路径。

Abstract

The hot-end components of high-temperature equipment are highly susceptible to erosion from high-temperature gases, thermal cycling, oxidation, CMAS corrosion and thermal stress with high-temperature equipment advancing toward high thermal efficiency and long service life under extreme operating conditions, which readily induces surface spalling, sintering degradation and structural failure of the equipment. Thermal barrier coatings (TBCs) have become a critical technical approach to improve the operating temperature tolerance and extend the service life of high-temperature components, so as to tackle the severe service challenges encountered in extreme working environments. The work aims to systematically review the research progress in the structural design and common preparation technologies of thermal barrier coatings, with the focus on analyzing the evolutionary logic and performance characteristics of double-layer and multi-layer structures. The structural features, performance advantages and primary failure mechanisms of double-layer TBCs applicable to three typical engineering substrates (nickel-based superalloys, steels and aluminum alloys) are analyzed. On the basis of the systematic analysis, the design criteria and application limitations of double-layer coatings under various service conditions are clarified. Furthermore, the structural optimization mechanisms of novel multi-layer TBCs are elaborated, including dual bond coat structures, multi-layer ceramic composite structures and multi-process coupled structures. The core differences between conventional YSZ ceramics and A₂B₂O₇ pyrochlore ceramics in thermal conductivity, high-temperature phase stability, sintering resistance and CMAS corrosion resistance are compared and analyzed, and the synergistic enhancement mechanism of multi-layer composite coatings in thermal insulation, mechanical compatibility and high-temperature durability is revealed. Meanwhile, the intrinsic correlations among process principles, microstructure characteristics and macroscopic service performance of coatings are investigated, with the focus on two mainstream industrial preparation technologies, namely atmospheric plasma spraying (APS) and electron beam physical vapor deposition (EB-PVD). The advantages, drawbacks and applicable scenarios of the lamellar porous structure fabricated by APS and the columnar crystal structure fabricated by EB-PVD are also summarized, and the process characteristics and application potential of emerging preparation technologies such as PS-PVD, SPS and HVOF are introduced. Based on TBC spraying and deposition technologies, extensive research has been carried out on two mainstream high-temperature ceramic coating systems (YSZ ceramics and A₂B₂O₇). Existing studies indicate that traditional double-layer YSZ-based TBCs serve as the mainstream coating systems for industrial applications due to the mature manufacturing processes and controllable costs. However, they suffer from inherent bottlenecks including ultra-high-temperature phase transformation failure, excessive TGO growth and thermal expansion mismatch. Multi-layer composite TBCs fabricated from A₂B₂O₇-type ceramics can effectively compensate for the high-temperature performance deficiencies of conventional coatings. They deliver outstanding comprehensive service performance under ultra-high-temperature environments above 1 400 ℃, representing a core development trend for next-generation thermal barrier coatings. However, the problems associated with complicated fabrication processes, great difficulties in interfacial stress regulation and high engineering costs are still unresolved. Key future directions are also proposed for high-performance thermal barrier coatings from multiple dimensions, including new material development, integration of novel processes and advanced structural design in response to the bottlenecks existing in the TBC field, such as insufficient adaptability of new materials, poor structural interface compatibility, limited precision of preparation processes.

导出引用

周心诺, 张平. 热障涂层的结构设计及常用制备技术研究进展[J]. 表面技术. 2026, 55(12): 1-18

ZHOU Xinnuo, ZHANG Ping. Research Progress on the Structural Design and Common Preparation Technologies of Thermal Barrier Coatings[J]. Surface Technology. 2026, 55(12): 1-18

中图分类号： TG174.4

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