Research Progress on &#x003b1;-Al2O3 Growth-Type High-Temperature Coatings/Bond Coats

ZHOU Bo; XIE Yun; PENG Xiao

doi:10.16490/j.cnki.issn.1001-3660.2026.19.001

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Surface Technology ›› 2026, Vol. 55 ›› Issue (19) : 1-20. DOI: 10.16490/j.cnki.issn.1001-3660.2026.19.001

Special Topic—Advanced Thermal Barrier Coating Technologies and Applications for Advanced Aero-engines and Gas Turbines

Research Progress on α-Al₂O₃ Growth-Type High-Temperature Coatings/Bond Coats

ZHOU Bo, XIE Yun^*, PENG Xiao

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Abstract

With the continuous increase in thrust-to-weight ratios and turbine inlet temperatures of aero-engines, high-temperature protective coatings, as a key technology ensuring the service reliability of hot-section components, are in urgent need of innovation, the performance and lifespan of thermal barrier coatings are closely related to their bond coats, therefore, the selection of the bond coats is crucial. This review systematically summarizes recent research progress on four typical α-Al₂O₃ growth-type coatings: diffusion aluminide coatings, MCrAlY overlay coatings, AlCoCrFeNi-based high-entropy alloy coatings, and refractory high-entropy alloy coatings. The analysis focuses on the influence mechanisms of composition design, phase structure regulation, reactive element doping, and fabrication processes on their high-temperature oxidation resistance.
Diffusion aluminide coatings have long been used on hot-section components of aero-engines due to their ability to rapidly form a protective Al₂O₃ scale. However, during long-term service at high temperatures, they suffer from severe interdiffusion with the substrate, Al depletion, and the precipitation of detrimental TCP phases. Recent studies have shown that the introduction of Re, Ru elements, and Ir can effectively inhibit Al interdiffusion and improve oxide scale adhesion. Additionally, constructing a Re-based diffusion barrier between the coating and the substrate can effectively slow down the interdiffusion between the coating and the substrate, thereby significantly enhancing the high-temperature oxidation resistance of the coating.
MCrAlY coatings, as one of the most widely used high-temperature protective coatings, achieve a good balance between oxidation resistance and mechanical properties. In recent years, research focus has gradually shifted from traditional compositional optimization to the synergistic regulation of microstructure and interfacial stability. The addition of reactive elements such as Y, Hf, and Zr can improve oxide scale adhesion through interfacial pinning, while nanocrystallization or nanocomposite electrodeposition can promote the selective oxidation of Al and Cr and promote the fast formation of α-Al₂O₃. Post-treatment techniques such as laser remelting and laser shock peening can effectively eliminate pores and cracks introduced during coating preparation, significantly improving coating density and the spallation resistance of the oxide scale.
AlCoCrFeNi-based high-entropy alloy coatings, due to the unique effects of high-entropy alloys and their excellent oxidation resistance at high temperatures, show great potential as a new generation of high-temperature protective coatings. Researches indicate that Al content is a key factor determining their oxidation resistance; high Al content promote the formation of a stable α-Al₂O₃ scale, but it also increases the fraction of the BCC phase and reduces toughness. Therefore, the design of FCC+BCC dual-phase or eutectic microstructures has become an important approach to balance oxidation resistance and mechanical properties. The addition of appropriate amounts of elements such as Y, Hf, Si, Nb, and Pt can further promote the formation of α-Al₂O₃ and reduce stress in the oxide scale.
Refractory high-entropy alloy coatings, owing to their high melting points and excellent high-temperature strength, are considered important candidate materials for ultra-high-temperature protective coatings above 1 300 ℃. However, they tend to form volatile or non-protective oxides after oxidation, leading to insufficient oxidation resistance. Current researches mainly focus on improving their oxidation resistance by adding Al, Cr, Si, and rare earth elements. Recent studies have shown that by precisely controlling the Al content and phase structure, a single and dense α-Al₂O₃ scale can be formed at 1 300 ℃, demonstrating the application potential of refractory high-entropy alloys in ultra-high-temperature environments.
In summary, the development of high-temperature protective coatings has shifted from traditional single-component optimization to multi-alloying, synergistic microstructural design, and comprehensive regulation of interfacial stability. Future research should pay further attention to the mechanisms of reactive element action, coating-substrate interdiffusion behavior, and the stress evolution in oxide scales. Combining advanced methods such as CALPHAD, first-principles calculations, and machine learning will accelerate the design and development of novel ultra-high-temperature protective coatings to meet the demands of higher service temperatures in next-generation aero-engines.

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Aluminide coatings / MCrAlY / AlCoCrFeNi / Refractory high-entropy alloy / High temperature oxidation

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ZHOU Bo, XIE Yun, PENG Xiao. Research Progress on α-Al₂O₃ Growth-Type High-Temperature Coatings/Bond Coats[J]. Surface Technology. 2026, 55(19): 1-20

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