Research Progress of Thermal Barrier Coatings for Internal Combustion Engines

LI Zhengdao; SHEN Chen; GUO Lei; WANG Fude; LING Likang; LI Dongqing; CHENG Yuxian; HE Qing

doi:10.16490/j.cnki.issn.1001-3660.2026.03.001

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Surface Technology ›› 2026, Vol. 55 ›› Issue (3) : 1-18. DOI: 10.16490/j.cnki.issn.1001-3660.2026.03.001

Special Topic—High-temperature Protective Coatings for Advanced Engines

Research Progress of Thermal Barrier Coatings for Internal Combustion Engines

LI Zhengdao^1,2, SHEN Chen³, GUO Lei^1,2,4,*, WANG Fude⁵, LING Likang^2,6, LI Dongqing⁷, CHENG Yuxian⁸, HE Qing^2,6,*

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Abstract

As the core component of traditional power systems, internal combustion engines (ICEs) have garnered joint attention from academia and industry regarding efficiency improvement and emission control, driven by the growing global energy needs and worsening environmental issues. Thermal barrier coatings (TBCs), as an advanced high-temperature protection technology, can significantly reduce the temperature of key ICE components such as pistons, cylinder heads, and exhaust systems. They minimize heat loss caused by coolants, thereby enhancing the thermal efficiency of ICEs and extending the service life of hot-end components. To endow TBCs with superior temperature regulation capabilities, enabling rapid response to changes in working gas temperature and maintaining the combustion chamber temperature within an optimal range, it is crucial for improving volumetric efficiency and avoiding problems like knocking. Low volumetric heat capacity and low thermal conductivity are key indicators for selecting TBC materials for ICE applications. This paper presents a systematic review on the application background, development status, coating materials, coating structures, and preparation methods of TBCs for ICEs. It is found that complex metal oxide ceramics, characterized by low volumetric heat capacity and low thermal conductivity, hold great promise in future research on TBC materials for ICEs. Examples include compounds such as Sr₂Ce₂Ti₅O₁₆ and K₂ZrF₆. In terms of structure, the design of a composite structure combined with functional layers facilitates the realization of the thermal floating layer concept and meets engineering application requirements. A typical structure consists of metal (with excellent thermal conductivity) + ceramic (which can be porous to reduce thermal conductivity) + functional layers. The functional layers can be tailored to specific needs. Additionally, gradient design for composite coatings—where the chemical composition, microstructure, or macro properties (thermal conductivity) of the coatings change continuously or stepwise along the thickness direction—offers significant advantages. Increasing the content of key components near the combustion chamber interface and decreasing it near the substrate interface helps low volumetric heat capacity materials store and release heat efficiently. This enhances ICE combustion efficiency and achieves a high thermal floating value. Regarding coating preparation methods, suspension plasma spraying (SPS) combines the advantages of plasma spraying and electron beam physical vapor deposition (EB-PVD). It can produce nanostructured coatings with few vertical cracks and extensive lamellar stacking, a structure that is highly conducive to meeting the low volumetric heat capacity requirement. Furthermore, TBCs prepared via SPS can effectively improve the fuel efficiency of light-duty diesel engines, providing a feasible technical pathway for ICE emission reduction and establishing itself as a preferred preparation method for ICE-specific TBCs. Finally, the paper outlines the research and development directions of TBCs for ICEs, as well as approaches to developing coatings with low volumetric heat capacity, high thermal insulation, and long service life. For instance, high-entropy design of complex oxide ceramics containing rare earth elements emerges as a promising solution. Besides, with the use of first-principles methods, the thermal physical properties of coating materials, such as thermal conductivity and specific heat capacity, can be simulated. By screening materials with low thermal conductivity and low specific heat capacity followed by experimentally validating them, the efficiency of discovering new materials that meet the requirements of TBCs for internal combustion engines can be enhanced. This review aims to provide guidance for the development of high-efficiency TBCs suitable for ICE applications.

Key words

internal combustion engine / thermal barrier coating / low volumetric heat capacity / coating structure / preparation method

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LI Zhengdao, SHEN Chen, GUO Lei, WANG Fude, LING Likang, LI Dongqing, CHENG Yuxian, HE Qing. Research Progress of Thermal Barrier Coatings for Internal Combustion Engines[J]. Surface Technology. 2026, 55(3): 1-18

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Funding

Open Project Fund of Engineering Research Center for High-temperature Protective Coating Technology and Equipment of China Machinery Industry (GCZX-2024-KF-04); Beijing Natural Science Foundation Funded Project (2232070); Innovation Project (D925BCD)