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

ZHOU Xinnuo; ZHANG Ping

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

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

Corrosion and Protection

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

ZHOU Xinnuo, ZHANG Ping^*

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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.

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thermal barrier coatings / structural design / preparation technology

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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

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Funding

National Natural Science Foundation of China (52271081); Undergraduate Innovation and Entrepreneurship Training Program of China University of Mining and Technology (X202510290745)