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Review | Open Access

Engineering design of feedstock powder and relevant thermal–mechanical performance of thermal/environmental barrier coatings

Xinchang Feng1, Fangwei Guo1,2(), Lirong Luo1, Yuzhang Wang3, Yun Long4, Xiaofeng Zhao1, Fei Pan5, Lei Guo6, Qingfeng Zeng7, Jing Feng8, Chunlei Wan9
Shanghai Key Laboratory of Advanced High-temperature Materials and Precision Forming, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
National Engineering Research Center of Special Equipment and Power System for Ship and Marine Engineering, Shanghai 200030, China
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
State Key Laboratory of Advanced Nuclear Energy Technology, Nuclear Power Institute of China, Chengdu 610213, China
Innovative Sensor Technology IST AG, Ebnat-Kappel 9642, Switzerland
School of Materials Science and Engineering, Tianjin University, Tianjin 300072, China
Tianmushan Laboratory, Hangzhou 311115, China
School of Materials Science and Engineering, Kunming University of Science and Technology, Kunming 650093, China
State Key Laboratory of New Ceramics and Fine Processing, School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China
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Abstract

The development of aeroengine with a high thrust-weight ratio poses great challenges for current top-coating thermal barrier coatings (TBCs) and environmental barrier coatings (EBCs) in service. Medium/high-entropy ceramics are highly promising candidate material for advanced TBCs/EBCs owing to their low thermal conductivity, high melting point, high-temperature stability, and calcium–magnesium–alumino–silicate (CMAS) resistance. Most feedstock powder used for medium/high-entropy TBCs/EBCs is prepared via traditional spray drying, which cannot fully exploit the advantages of multicomponent ceramics. The density, sphericity, inner structure, and flowability of feedstock powder affect their melting state during the thermal spraying process, which strongly affects the microstructure and properties of the deposited coatings. Therefore, the deposited coatings exhibit phase segregation, amorphous phases, and microstructure defects owing to unpredictable variations in feedstock powder with random morphologies and structures. Here, the structure and properties of feedstock powder prepared by state-of-the-art granulation technologies and their influences on the deposited coatings were systematically investigated, which can provide guidance for configuration optimization of feedstock powder and the manufacturing accuracy of the deposited coating. This review aims to bridge the gap between cutting-edge ceramics and advanced engineering technologies, thus providing concrete background knowledge and crucial guidelines for designing and developing TBCs/EBCs.

Keywords

thermal/environmental barrier coatings (TBCs/EBCs)spraying ceramic powdermultiscale structure controlhigh-entropy ceramicsthermal-mechanical performance

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Journal of Advanced Ceramics
Volume 14 Issue 2,
February 2025
Article number: 9221033
DOI: 10.26599/JAC.2025.9221033
Cite this article:
Feng X, Guo F, Luo L, et al. Engineering design of feedstock powder and relevant thermal–mechanical performance of thermal/environmental barrier coatings. Journal of Advanced Ceramics, 2025, 14(2): 9221033. https://doi.org/10.26599/JAC.2025.9221033
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