This book addresses the recent trends in thermal and environmental barrier coatings and their applications in extreme environments. It introduces the state of the art in coating materials and processes for high and ultrahigh-temperature environments and identifies areas for improvement in materials selection, performance upgrades, design considerations, and manufacturing methods. This book also covers fundamental studies involving modelling, creating coating architectures, coating preparation methods, and coating capability throughout a wide temperature range. The book examines a variety of high-temperature coatings prepared through various synthesis processes such as thermal spraying, electron beam evaporation, and sol–gel methods. This book also covers ultrahigh-temperature ceramic (UHTC) materials and provides a brief overview of the synthesis method, densification processes, and coating methods along with the properties and applications of emerging high entropy UHTCs.
With contributions from international researchers active in the field, this edited book features the most recent and up-to-date literature references for a broad readership consisting of academic and industrial professionals. It is suitable for graduate students as well as materials scientists and engineers working in the area of high and ultrahigh-temperature ceramic materials.
Author(s): Amirhossein Pakseresht (editor), Kamalan Kirubaharan Amirtharaj Mosas (editor)
Publisher: Springer
Year: 2023
Language: English
Pages: 505
Preface
Acknowledgements
About This Book
Contents
Thermal Barrier Coatings
New Materials for Thermal Barrier Coatings: Design, Manufacturing and Performance
1 Introduction
2 Design of TBC Systems
3 Common Technologies Employed for TBC Manufacturing
3.1 Thermal Spraying Processing Technologies
3.2 EB-PVD Deposition Method
3.3 Additive Manufacturing
4 TBC Materials
4.1 Zirconia-Based Materials
4.2 Alternative Compositions
5 Multilayered TBCs
6 High-Temperature Behavior and Common TBC Failure Mechanisms
6.1 TGO Growth and Delamination
6.2 Sintering of Porous TBC Microstructure
6.3 Microstructural Damage Promoted by CMAS Infiltration
7 Drawing Next Perspectives
References
Trends and Perspectives in Mitigating CMAS Infiltration in Thermal Barrier Coating
1 Introduction
2 Suspension Plasma Spray
2.1 Process Description
2.2 Process Parameters Influencing the Coating Formation
2.3 Challenges of SPS Coatings: The Case of High-Turbine Blade TBCs
3 Damage Mechanisms of CMAS Infiltration
3.1 Chemical Mechanisms of CMAS Infiltration Attack
3.2 Mechanical Damages Induced by CMAS Infiltration Attack
4 Methodologies for Characterizing Damage to SPS Coatings, Including CMAS
4.1 Isothermal Cycling Test
4.2 Thermal Gradient Cycling Test
5 Current Potential Solutions Against the CMAS Attack
5.1 Material Strategies
5.2 Coating Strategies
6 Conclusion
References
New Materials for Thermal Barrier Coatings
1 Metal Oxide and Their Doped Materials
1.1 Crystal Structure and Thermal Properties of Materials
1.2 Effect of Doping Modification on Materials
1.3 Preparation and Properties of YSZ TBCs
1.4 Application of Hafnium Oxide in TBCs
2 Rare Earth Zirconate
2.1 Crystal Structure of Rare Earth Zirconate in TBCs
2.2 Properties of Rare Earth Zirconate TBCs
2.3 Modification of Rare Earth Zirconate
2.4 Properties of Nanostructured Rare Earth Zirconate Coatings
3 Rare Earth Cerate
3.1 Crystal Structure of Rare Earth Cerate in TBCs
3.2 Properties of Rare Earth Cerate TBCs
3.3 Modification of Rare Earth Cerate
4 Rare Earth Hexaluminate
4.1 Synthesis and Crystal Structure of Hexaluminate Materials
4.2 Preparation and Properties of Hexaluminate TBCs
4.3 Other Rare Earth Hexaluminate TBCs Materials
5 Other TBCs Materials
5.1 Titanate
5.2 Perovskite Structure
5.3 Rare Earth Niobate
5.4 Rare Earth Tantalate
6 Trend of TBCs Development
References
Recent Developments on Al2O3-Based Thermal Barrier Coatings
1 Introduction
2 Coating Process and Design
2.1 Production of Alumina-Based Thermal Barrier Coatings
2.2 Design of Alumina-Based Thermal Barrier Coatings
3 Thermal Properties and Thermal Tests
3.1 Thermal Conductivity
3.2 Thermal Cycling Tests
4 Mechanical Properties
5 Calcia-Magnesia-Alumina-Silica (CMAS) and Hot Corrosion Resistance Performance
6 Laser Surface Modification
6.1 Laser Surface Modification of Al2O3-Based Thermal Barrier Coatings
7 Conclusion
8 Suggestions
References
Zirconia-Based Thermal Barrier Coatings Systems for Aero-Industry
1 Introduction
1.1 Current Trends in Ceramic Materials—Thermal Barrier Coatings as Protection Systems
1.2 The Development Process of TGO by Thermal Treatment
2 Materials and Methods
2.1 Suitable Deposition Methods for Hot Structural Components
2.2 High-Quality Testing Methods—Thermal Shock Resistance Test
2.3 Classical Thermal Testing of Materials in the Defence and Security Industry. Limitations of the Process
3 Results and Discussion
3.1 Thermal Shock Resistance Test
3.2 Thermal Barrier Coating's Structure—Composition and Microstructural Evaluation
4 Conclusions
References
Multilayered Coatings by Thermal Spray for High-Temperature Applications
1 Introduction: Role of a Thermal Barrier and an Environmental Barrier
2 Thermal Barrier Coatings by Thermal Spray
3 Environmental Barrier Coating by Thermal Spray
4 Multilayer Coating Architectures
5 Mechanical and Chemical Considerations
6 Conclusions
References
Environmental Barrier Coatings
Environmental Barrier Coatings (EBCs) for Ceramic Matrix Composites
1 Application Background of EBCs
2 Material Systems of EBCs
2.1 Mullite and YSZ
2.2 BaxSr1-xAl2Si2O8 (BSAS)
2.3 Rare Earth Silicate
2.4 High-Entropy Rare Earth Silicate and Modification of Si Layer
2.5 Aluminate
3 Preparation Technology of EBCs
3.1 Atmospheric Plasma Spraying (APS)
3.2 Electron Beam Physical Vapor Deposition (EB-PVD)
3.3 Plasma Spraying Physical Vapor Deposition (PS-PVD)
3.4 Other Preparation Technology
4 Mechanical Properties of EBCs
4.1 Fracture Toughness
4.2 Bonding Strength
5 High-Temperature Failure Behavior of EBCs
5.1 Water Oxygen Corrosion
5.2 High-Temperature Oxidation
5.3 Calcium-Magnesium-Alumino-Silicate Melts (CMAS) Corrosion
6 Summary and Future Direction
References
Environmental Barrier Coatings (EBCs) for Silicon-Based Ceramics and Composites
1 Introduction
1.1 Mechanical Properties of Silicon-Based Ceramics and Composites
1.2 Failure of Silicon-Based Ceramics and Composites in Service
1.3 Performance Requirements of EBCs for Hot-Section Components
2 Development for EBCs Materials
2.1 The First-Generation EBCs
2.2 The Second-Generation EBCs
2.3 The Third-Generation EBCs
3 Fabrication and Characterization of EBCs
3.1 Fabrication Methods
3.2 Structure and Performance Characterization
3.3 Properties
3.4 Improvement Strategies for Properties of EBCs
4 Main Failure Mechanisms of EBCs
4.1 Intrinsic Failure in EBCs Without Interaction to Corrosive Media
4.2 Failure Mechanisms of EBCs Under Attacks of Corrosive Media
5 Conclusions and Outlook
References
Development of Silicates and Spraying Techniques for Environmental Barrier Coatings
1 Background
2 EBC Material Candidates
2.1 Al6Si2O13 (Mullite) and Ba1-xSrxAl2Si2O8 (BSAS)
2.2 Rare-Earth Silicates
3 Properties and Corrosion Behaviour of Rare-Earth Silicates for EBC
3.1 Phase Stability and Thermal Properties
3.2 Resistance to Corrosion by Water Vapour
3.3 Resistance to Corrosion by Volcanic Ash
4 Thermal Spraying Techniques for EBCs
4.1 Atmospheric Plasma Spraying (APS)
4.2 Suspension Plasm Spraying (SPS)
4.3 Low-Pressure Plasma Spraying (LPPS)
4.4 High-Velocity Oxygen Fuel (HVOF)
5 Summary and Perspectives
References
1D Micro/Nanomaterial Toughened Ceramic Coatings for Carbon/Carbon Composites
1 Introduction
2 Preparation Methods of Ceramic Coatings
3 Fabrication of 1D Micro/nanomaterial-Reinforced Ceramic Coatings for C/C Composites
4 CNT-Reinforced Ceramic Coatings on C/C Composites
5 SiC Whisker/nanowire-Reinforced Ceramic Coatings for C/C Composites
5.1 SiC Whisker-Reinforced Ceramic Coatings on C/C Composites
5.2 SiC Nanowire-Reinforced Ceramic Coatings on C/C Composites
6 UHTC Nanowire-Reinforced Ceramic Coatings on C/C Composites
6.1 HfC Nanowire-Reinforced Ceramic Coatings on C/C Composites
6.2 ZrC Nanowire-Reinforced Ceramic Coatings for C/C Composites
7 Core–shell Structured Nanowire-Reinforced Ceramic Coatings for C/C Composites
8 Multiple Nano/micro-materials Co-reinforced Ceramic Coatings for C/C Composites
9 Summary
References
Oxidation and Thermal Cycle Behavior of Yb2Si2O7-c-AlPO4-SiCw-Mullite Multilayer Coatings
1 Introduction
2 Experimental
2.1 Coating Preparation
2.2 Isothermal Oxidation Tests
2.3 Burner Rig Tests
2.4 Coating Characterization
3 Results and Discussion
3.1 Microstructure and Phase Composition of the Coatings
3.2 Isothermal Oxidation Properties of Coatings
3.3 Thermal Cycle Properties of Coatings
4 Conclusions and Outlook
References
Space Environment Effects on Advanced Ceramic Coating for Aerospace Thermal-Proof Re-entry Systems
1 Introduction
2 Materials
2.1 Ceramic Substrates
2.2 Ceramic Coating
3 Experimental Setup
3.1 Thermal Characterization
3.2 Outgassing Test
3.3 AtOx/UV Exposure
4 Experimental Results
4.1 Thermal Stress Behavior
4.2 Outgassing Properties
4.3 AtOx/UV Oxidative Erosion
5 Conclusions and Outlooks
References
Ultra High Temperature and High Temperature Coatings
Recent Advances in Ultra-High-Temperature Ceramic Coatings for Various Applications
1 Introduction
2 New UHTC Material Systems
2.1 Boride-Based UHTCs
2.2 Carbide-Based UHTCs
2.3 Nitride-Based UHTCs
3 Synthesis Techniques of UHTCs
3.1 Powder Synthesis Method
3.2 Sol–Gel Method
4 Densification Methods for UHTCs
4.1 Pressureless Sintering
4.2 Reactive Sintering
4.3 Hot Pressing
4.4 Reactive Hot Pressing
4.5 Spark Plasma Sintering
4.6 Microwave Sintering
4.7 Laser Sintering
5 Coating Methods
5.1 Chemical Vapour Deposition (CVD) Method
5.2 Physical Vapour Deposition Method
5.3 Plasma Spray Method
6 Properties of UHTCs
6.1 Mechanical Properties of UHTCs
6.2 Thermal Shock Resistance of UHTCs
7 Simulation and Modelling Studies on UHTCs
8 Applications of UHTCs
8.1 Oxidation Protective UHTC Coatings
8.2 Thermal Barrier UHTC Coatings
9 High Entropy UHTCs
9.1 Properties of High Entropy UHTCs
9.2 Applications of High Entropy UHTCs and Future Research Directions
10 Summary and Outlooks
References
Ultra-High-Temperature Ceramic Coatings ZrC, ZrB2, HfC, and HfB2
1 Introduction
2 Zirconium Carbide Coatings
3 Zirconium Boride Coatings
4 Hafnium Carbide Coatings
5 Hafnium Boride Coatings
6 Coating Techniques of Ultra-High-Temperature Ceramic Coatings
6.1 Zirconium Carbide Coatings
6.2 Zirconium Boride Coatings
6.3 Hafnium Carbide Coatings
6.4 Hafnium Boride Coatings
7 Characterization and Microstructure of Ultra-High-Temperature Ceramic Coatings
7.1 Zirconium Carbide Coatings
7.2 Zirconium Boride Coatings
7.3 Hafnium Carbide Coatings
7.4 Hafnium Boride Coatings
8 Properties of Ultra-High-Temperature Ceramic Coating
8.1 Zirconium Carbide Coatings
8.2 Zirconium Boride Coatings
8.3 Hafnium Carbide Coatings
8.4 Hafnium Boride Coatings
9 Challenges in Coating Technology
10 Conclusion and Future Work
References
High-Temperature W/ZrC Composite Coatings
1 Introduction
2 Fabrication of Preforms
2.1 Gel-Casting Based on Low-Toxic Polymers
2.2 Non-toxic Polymer-Based Gel-Casting
2.3 Rheological Behavior of WC Slurry
3 W/ZrC Composites
3.1 In-situ Reactive Sintering
3.2 Reactive Infiltration-Based Method
4 W-ZrC Coating
4.1 Properties
5 Summary
6 Future Scope
References
