热障涂层高温失效机理与增效策略研究进展

武晓辰; 季现涛; 孙瀚荣; 张佩凯; 崔越; 殷凤仕; 马宗青; 史程程; 赵凯; 孙金钊

doi:10.16490/j.cnki.issn.1001-3660.2026.12.002

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表面技术 ›› 2026, Vol. 55 ›› Issue (12) : 19-42. DOI: 10.16490/j.cnki.issn.1001-3660.2026.12.002

腐蚀与防护

热障涂层高温失效机理与增效策略研究进展

武晓辰¹, 季现涛¹, 孙瀚荣¹, 张佩凯², 崔越³, 殷凤仕¹, 马宗青¹, 史程程¹, 赵凯^1*, 孙金钊^1*

作者信息 +

Research Progress on High-temperature Failure Mechanism and Efficiency Enhancement Strategy of Thermal Barrier Coatings

WU Xiaochen¹, JI Xiantao¹, SUN Hanrong¹, ZHANG Peikai², CUI Yue³, YIN Fengshi¹, MA Zongqing¹, SHI Chengcheng¹, ZHAO Kai^1*, SUN Jinzhao^1*

Author information +

文章历史 +

摘要

热障涂层（TBCs）作为航空发动机和燃气轮机高温部件的关键防护技术,其高温失效行为与增效策略研究对保障“两机专项”实施和提升装备服役寿命具有重要意义。随着航空发动机向高推重比、高燃气温度方向发展,传统氧化钇稳定氧化锆（YSZ）涂层在长期超1 200 ℃服役环境下面临相失稳、烧结致密化、抗腐蚀性能下降等严峻挑战。本文系统综述了热障涂层在高温环境下因氧化、残余应力及腐蚀等多场耦合作用导致的复杂失效机理,重点分析了热生长氧化物（TGO）增厚与界面波纹化、YSZ中四方相向单斜相转变引发的相变开裂、CMAS与熔盐渗透导致的化学腐蚀,以及水氧协同侵蚀等典型失效模式的动态关联性与非线性特征。在此基础上,围绕涂层材料组分、微观结构设计与后处理调控三个维度,系统总结了包括新型陶瓷材料、多组元固溶体设计、反应型元素掺杂等组分优化策略,阐述了层状、柱状与功能梯度结构等微观构筑方法及其在隔热、应变容限与结合强度方面的协同调控机制,并评述了激光重熔、真空热处理等后处理技术在愈合缺陷、优化TGO生长与提升表面完整性方面的调控作用。综述归纳表明,以1 200 ℃热循环为例,BPS涂层在250次循环后仍保持完整,而8YSZ在150次后已出现起皮,表现出≥67%的寿命提升趋势,热处理亦可显著抑制黏结层损伤演化,在等温氧化400 h后氧化物含量降幅约80%,孔隙率降幅约90%。本文旨在通过对热障涂层失效机理与增效策略的系统梳理,以期为下一代高性能、长寿命热障涂层的理性设计与工程应用提供理论依据与技术参考。

Abstract

Thermal barrier coatings (TBCs) have become one of the most important surface protection technologies for high-temperature components in aero-engines and gas turbines because of their excellent thermal insulation capability, their ability to reduce substrate temperature, and their significant contribution to extending component service life under severe thermal environments. In recent years, with the continuous increase in thrust-to-weight ratio and turbine inlet temperature, the service conditions of hot-section components have become increasingly harsh, and the requirements for the thermal stability, corrosion resistance, and long-term durability of TBC systems have been greatly intensified. Under such conditions, conventional yttria-stabilized zirconia (YSZ)-based coatings face severe challenges, including phase instability, sintering-induced densification, thermally grown oxide (TGO) thickening, and environmental attacks caused by CMAS, molten salts, and water-vapor-containing atmospheres. The high-temperature failure mechanisms and efficiency enhancement strategies of TBCs are systematically reviewed, and the recent research progress in failure behavior and durability improvement is discussed.
Starting from the classification of main high-temperature failure mechanisms, the degradation processes of TBCs under oxidation, residual stress, and corrosion conditions are summarized, and the interaction characteristics and damage evolution paths of these failure modes are clarified. The Oxidation failures are mainly associated with oxygen ingress through pores and microcracks, the formation and continued growth of the TGO layer, the depletion of Al in the bond coat, and the eventual formation of non-protective oxides, all of which progressively weaken interfacial integrity and promote crack initiation and coating spallation. Stress-related failures include quenching stress generated during deposition, thermal mismatch stress caused by differences in thermal expansion among the ceramic top coat, TGO, and bond coat during thermal cycling, and phase-transformation stress caused by the tetragonal-to-monoclinic transformation of YSZ under high-temperature or corrosive environments. Corrosion failures are primarily induced by the infiltration and chemical attack of molten deposits such as CaO-MgO-Al₂O₃-SiO₂ (CMAS), sulfate-vanadate salts, and water-vapor-containing atmospheres, which destabilize the ceramic phase, accelerate microstructural degradation, and intensify interfacial damage.
Based on these three categories of failure mechanisms, the coupled degradation behavior of TBCs under realistic service environments is further analyzed. It is pointed out that TBC failures are not controlled by a single factor, but rather by the synergistic action of oxidation, stress accumulation, phase transformation, and environmental corrosion. TGO thickening and interfacial rumpling can amplify local stress concentration; CMAS and molten salts can dissolve stabilizing components and induce brittle reaction products and phase transformation; water vapor can accelerate oxide instability and promote ceramic degradation. These processes interact in a nonlinear manner and form a positive feedback loop involving chemical reaction, structural evolution, crack propagation, and interfacial delamination, ultimately resulting in accelerated coating spallation. Therefore, the study of multiphysics field coupled failure has become a key issue in improving the reliability and service lifetime of next-generation TBC systems.
Based on the understanding of failure behaviors, recent advances in efficiency enhancement strategies are reviewed from three aspects, namely material composition design, microstructure optimization, and post-treatment regulation. In terms of material design, the development of novel top-coat ceramics, multi-component solid-solution systems, and reactive doping strategies is introduced, and their roles in improving phase stability, reducing thermal conductivity, suppressing sintering, and enhancing resistance to CMAS and molten salt corrosion are discussed. In terms of microstructure design, lamellar structures prepared by atmospheric plasma spraying (APS), columnar coatings fabricated by electron-beam physical vapor deposition (EB-PVD), and functionally graded architectures are compared, and their advantages in thermal insulation, strain tolerance, crack deflection, and interfacial stress mitigation are clarified. In terms of post-treatment processing, laser remelting and vacuum heat treatment are mainly used to heal as-sprayed defects, seal near-surface pores, regulate TGO growth, and promote the formation of a dense and protective α-Al₂O₃ layer, thereby improving the overall durability of the coating system.
Representative results demonstrate that these enhancement strategies can effectively improve the service life of coatings. Under thermal cycling at 1 200 ℃, the bi-phase solid-solution coating remains intact after 250 cycles, whereas conventional 8YSZ exhibits delamination after 150 cycles, showing a service time extension trend of no less than 67%. Heat treatment can also significantly alleviate bond-coat degradation; after 400 h of isothermal oxidation, the oxide content decreases by about 80% and the porosity decreases by about 90%. By systematically summarizing the current understanding of failure mechanisms and enhancement pathways, this review aims to provide a theoretical basis and technical reference for the rational design, microstructure engineering, and process optimization of advanced TBC systems, and to support the development of more reliable and longer-lasting thermal protection technologies for high-performance propulsion and power-generation applications.

导出引用

武晓辰, 季现涛, 孙瀚荣, 张佩凯, 崔越, 殷凤仕, 马宗青, 史程程, 赵凯, 孙金钊. 热障涂层高温失效机理与增效策略研究进展[J]. 表面技术. 2026, 55(12): 19-42

WU Xiaochen, JI Xiantao, SUN Hanrong, ZHANG Peikai, CUI Yue, YIN Fengshi, MA Zongqing, SHI Chengcheng, ZHAO Kai, SUN Jinzhao. Research Progress on High-temperature Failure Mechanism and Efficiency Enhancement Strategy of Thermal Barrier Coatings[J]. Surface Technology. 2026, 55(12): 19-42

中图分类号： TG174.4

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