Research Progress on Thermal Barrier Coatings for Extreme High-Temperature Service Environments: Material Systems, Preparation Techniques, and Failure Control

GE Zaibing; YIN Yichuan; MA Wen; LI Qi; SUN Zhen; BAI Yu

doi:10.16490/j.cnki.issn.1001-3660.2026.14.001

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Surface Technology ›› 2026, Vol. 55 ›› Issue (14) : 1-16. DOI: 10.16490/j.cnki.issn.1001-3660.2026.14.001

Research Progress on Thermal Barrier Coatings for Extreme High-Temperature Service Environments: Material Systems, Preparation Techniques, and Failure Control

GE Zaibing, YIN Yichuan^*, MA Wen, LI Qi, SUN Zhen, BAI Yu^*

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Abstract

Thermal barrier coatings (TBCs) represent the core enabling technology for high-temperature components in aero-engines and industrial gas turbines to operate beyond the inherent temperature limits of nickel-based superalloys. The structural integrity and long-term durability of TBC systems directly determine the thermal efficiency, thrust-to-weight ratio, operational reliability, and carbon emission levels of advanced power equipment. With the global push for carbon neutrality and the rapid development of high-parameter gas turbines and emerging hydrogen-fueled/hydrogen-blended combustion technologies, the service environments of TBCs have evolved dramatically. The conventional single high-temperature oxidation environment has been replaced by complex multi-factor coupled scenarios characterized by ultra-high temperatures exceeding 1 500 ℃, extremely high water vapor partial pressures, intense thermal cycling with large temperature gradients, and corrosive calcium-magnesium-alumina-silicate (CMAS) molten deposits from fuel impurities. These unprecedented harsh conditions have pushed the performance limits of the traditional coating system consisting of 8wt.% yttria-stabilized zirconia (8YSZ) ceramic top coat and MCrAlY metallic bond coat. Specifically, 8YSZ undergoes detrimental tetragonal-to-monoclinic phase transformation above 1 200 ℃ accompanied by ~4% volume expansion, while MCrAlY bond coats suffer from accelerated oxidation and Al depletion in high-humidity environments, severely limiting the further performance upgrading and service life extension of high-temperature thermal protection components.
This paper presents a comprehensive review of recent advances in TBC technologies, focusing on the three fundamental structural units: superalloy substrate, metallic bond coat, and ceramic thermal insulation layer. The evolutionary trends of ceramic coating materials are systematically discussed, highlighting the transition from conventional YSZ to novel rare earth zirconates, tantalates, niobates, and advanced multi-layer composite architectures. These emerging materials exhibit superior comprehensive performance, including lower thermal conductivity, higher phase stability up to 1 600 ℃, and enhanced CMAS corrosion resistance compared to traditional 8YSZ. Multi-layer composite designs, which strategically combine the high toughness of YSZ with the excellent high-temperature stability of rare earth tantalates, have emerged as a promising approach to balance thermal insulation performance and mechanical reliability.
For bond coat development, the review examines the latest progress in high-entropy alloy bond coats and noble metal (Pt, Pd)-modified aluminide coatings. High-entropy alloy bond coats with multi-principal element solid solution structures demonstrate exceptional high-temperature strength and oxidation resistance, while noble metal modification effectively promotes the formation of continuous, dense, and slow-growing α-Al₂O₃ thermally grown oxide (TGO) layers and suppresses the generation of harmful spinel phases. Special emphasis is placed on their effective modulation of TGO growth kinetics, morphology, and mechanical properties at the ceramic-bond coat interface, which is critical for improving interfacial adhesion and extending coating service life.
Furthermore, a detailed comparative analysis is performed on the four mainstream coating deposition techniques: atmospheric plasma spraying (APS), electron beam physical vapor deposition (EB-PVD), plasma spray-physical vapor deposition (PS-PVD), and solution precursor plasma spraying (SPPS). Their respective advantages and limitations are evaluated in terms of microstructural design capability, interfacial bonding quality, thermal insulation performance, production cost, and engineering scalability. The dominant failure mechanisms of TBCs under extreme service conditions are also systematically analyzed, including thermal stress mismatch-induced delamination, thermal cyclic fatigue damage, high-temperature oxidation degradation, water-oxygen synergistic corrosion, and CMAS infiltration-induced failure, with particular attention to the synergistic effects between multiple degradation factors.
Finally, addressing the unique high-humidity and high-oxygen service environment of hydrogen-fueled gas turbines, this review identifies the critical development directions for next-generation TBCs: ultra-high temperature tolerance, extended service life, multi-functional integration, and intelligent design incorporating machine learning-assisted material genome engineering and in-situ health monitoring. The insights provided in this work aim to offer valuable theoretical guidance and technical references for the rational material design, process optimization, and life prediction of high-temperature protective coatings for extreme environment applications.

Key words

thermal barrier coatings / ceramic thermal insulation layer / bond coat / preparation process / failure mechanism / high-temperature corrosion

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GE Zaibing, YIN Yichuan, MA Wen, LI Qi, SUN Zhen, BAI Yu. Research Progress on Thermal Barrier Coatings for Extreme High-Temperature Service Environments: Material Systems, Preparation Techniques, and Failure Control[J]. Surface Technology. 2026, 55(14): 1-16

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Funding

The National Natural Science Foundation of China (52572074); The Science and Technology Planning Project of Inner Mongolia Autonomous Region (2025KYPT0027); The Science and Technology Planning Project of Inner Mongolia Autonomous Region (2025YFHH0002); The Scientific Research Startup Fund of Inner Mongolia University of Technology (BS2025065)