Thermal barrier coatings overview: Design, manufacturing, and applications in high-temperature industries

Kunal Mondal, Luis Nuñez, Calvin M. Downey, Isabella J. Van Rooyen

Research output: Contribution to journalArticlepeer-review

80 Scopus citations

Abstract

Today's competitive world economy is creating an indispensable demand for increased efficiency of engineering components that operate in harsh environments (i.e., very high-temperature, corrosive, or neutron irradiation environments), for applications in the energy, automotive, aerospace, electronics, and power industries. Increased research is being done on thermal barrier coatings (TBCs) for protecting such components, since the versatility of manufacturing techniques and the scale of deployment result in increased life, economics, performance, and durability. This review focuses on the advances that led to using TBCs for component life extension and, more recently, as an integral part of advanced component design for high-temperature and other types of harsh environments, such as those found in nuclear-related applications. Factors that led to state-of-the-art advanced coating-fabrication techniques [e.g., electron-beam physical vapor deposition (EB-PVD), plasma spray deposition, and electrophoretically deposited TBCs, as well as functionally graded material (FGM) manufacturing] have also been emphasized in current coating R&D. This review explores the current state of TBCs, i.e., the latest advances regarding their fabrication and performance, associated challenges, and recommendations for their future use in aerospace, nuclear, high-temperature, or otherwise harsh environments.

Original languageEnglish
Pages (from-to)6061-6077
Number of pages17
JournalIndustrial and Engineering Chemistry Research
Volume60
Issue number17
DOIs
StatePublished - May 5 2021
Externally publishedYes

Funding

This research was funded by the INL Laboratory Directed Research & Development (LDRD) Program under DOE Idaho Operations Office Contract DE-AC07-05ID14517. The APC was funded by the same project grant.

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