THERMAL BARRIER COATINGS: RECENT DEVELOPMENTS, CHALLENGES, AND PROBABLE SOLUTIONS

Gaurav Prashar and Hitesh Vasudev
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Gaurav Prashar: Rayat Bahra Institute of Engineering & Nano Technology, Hoshiarpur VPO-Bohan, Distt. Hoshiarpur 146104, Punjab, India
Hitesh Vasudev: ��School of Mechanical Engineering, Lovely Professional University, Phagwara 144411, Punjab, India

Surface Review and Letters (SRL), 2025, vol. 32, issue 05, 1-17

Abstract: The lifespan and performance of the industrial components used in aero engine’s and IC engines can be considerably increased by depositing thermal barrier coatings (TBCs). High-pressure gas turbines’ rotor blades and stator vanes are some of the world’s most heavily loaded engineering parts. In order to safeguard such components, more research is being conducted on TBCs, since the size of deployment and the production techniques used lead to improved life, economics, efficiency, and durability. This paper concentrates on the technological developments in the field of TBCs over the past few years in order to achieve maximum output. Current coating R&D has also placed an emphasis on the factors that contributed to the development of cutting-edge advanced coating-fabrication techniques, such as electron-beam physical vapor deposition (EB-PVD), suspension plasma spray (SPS), additive manufacturing (AM), functionally graded material (FGM) and incorporation of artificial intelligence (AI) in manufacturing of TBCs. This paper examines the current state of TBCs, including the most recent developments in terms of their performance and manufacturing, associated challenges, and suggestions for their potential usage in high temperature sector.

Keywords: Gas turbine; additive manufacturing; thermal barrier coating; top coat; SPS; EB-PVD (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1142/S0218625X22400078

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