Materials Today: Proceedings 45 (2021) 1529–1534

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Materials Today: Proceedings

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Thermal barrier coatings for high temperature applications – A short

review
D. Chellaganesh ⇑, M. Adam Khan, J.T. Winowlin Jappes
Department of Mechanical Engineering & Centre for Surface Engineering, Kalasalingam Academy of Research and Education, Krishnankoil 626126, Tamilnadu, India

a r t i c l e i n f o a b s t r a c t

Article history: This review paper aims to portray the work done by various researchers in the domain of thermal barrier
Received 21 July 2020 coatings. Thermal barrier coatings (TBCs) are provided to minimize the temperature of components in the
Received in revised form 31 July 2020 field of aviation and power generation sector to increase the components performance and efficiency. The
Accepted 2 August 2020
review was made in the aspects of methodology adapted for the coating process, thickness of various
Available online 14 October 2020
coatings, materials chosen for coating, anatomy of TBC and mechanism of thermally grown oxides
(TGO). Based on the survey, majority of the articles are found employed the process of spray coating
Keywords:
for TBC. On the hand, literatures depicts that the preferred materials for TBS is ceramics due to lack of
Coatings
Oxidation
thermal conductivity and high corrosion and wear resistance. The review expose that the TBCs are more
Corrosion resistant to oxidation, corrosion, erosion and it act as a good thermal insulator to protect the material
TBCs high temperature environment.
TGO Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Advances in Materials Research – 2019.

1. Introduction Corrosion causes a major problem in safety and environmental

A gas turbine is a combustion-based system which has been
used for several decades in the field of aviation, electricity genera-
tion and mechanical drive applications for several years. The life of
the turbine engine material is almost 50,000 h operating between
900 °C and 1100 °C under the aggressive environment [1]. During
the operating condition, engine components have to face the gas
effluent from the combustion fuels and halides from the atmo-
spheric environment. Oxidation and corrosion are occurred in the
material due to high temperature. Metals and alloys at high tem-
perature in the combustion chamber readily oxidize in the pres-
ence of abundant air [2]. Oxidation of the materials cannot be
avoided despite improvements the quality of the materials [3]. In
addition to hot air, the combustion fuel also contributes to gas tur-
bine damage. The fuels have contaminants such as sulfur, chlorine,
alkali fuels and vanadium after combustion. Alloy materials when
reacting with oxygen leads to cause oxidation whereas other prod-
ucts in the combustion affect the oxidation behaviour of the alloys
[2].
⇑ Corresponding author.
E-mail address: mechchellam@gmail.com (D. Chellaganesh).
hazards [4]. A current research shows that the total cost worldwide
corrosion worldwide amounts to 2.5 trillion US dollars per year
[5]. Hence appropriate materials are essential to protect the tur-
bine components from erosion and to promote corrosion resis-
tance. Superalloy materials are mostly employed in high
temperature resisting regions such as the compressor and combus-
tion chambers leading to turbine sections. They are induced to face
a lot of surface-related problems. Nickel-based superalloy which is
utilized for use in elevated temperatures has excellent strength,
toughness, and resistance for degradation in corrosive or oxidizing
environments at the higher temperature. Among the corrosion
mitigation measures, protective coatings are the most widely used
to save the material from further oxidation and corrosion [5]. The
purpose of surface modification is to increase or enhance surface
properties which helpful to protect the material from oxidation,
corrosion and oxidation. The number of the coating process and
coating materials is available to protect the component [6–8].
In the past 40 year’s decades, the development of coatings is
enhanced to resist the coatings degradation under the operating
conditions. TBCs are act as thermal insulation for critical compo-
nents in the field of aero and gas turbines industry. Its helps to pro-
tect the components from the oxidation, corrosion, abrasion and
erosion wear resistance (Fig. 1).

https://doi.org/10.1016/j.matpr.2020.08.017
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Advances in Materials Research – 2019.
D. Chellaganesh, M. Adam Khan and J.T. Winowlin Jappes
Fig. 1. Coating deposition process.
In the present research scenario, the industry sectors are facing
a major issue like a premature failure of the component. That is the
before service life due to the aggressive service conditions are
damaging the life of the component. To enhance the life cycle of
the materials, the surface area of the same must be protected with
high resistance coating to save from material degradation. The
need for coating is to protect the component from environmental
degradation and also from elevated temperature exposure. At the
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Materials Today: Proceedings 45 (2021) 1529–1534
same time, maintaining their mechanical property without sacri-
fice. The appropriate coating must be selected to achieve the
demand requirements.
2. Coatings
Coating methodology is used to protect the material from sev-
ere degradation. The various methods of coatings and materials
D. Chellaganesh, M. Adam Khan and J.T. Winowlin Jappes Materials Today: Proceedings 45 (2021) 1529–1534

are existing in current research. This process consists of different Table 2

on-line and off-line parameters. The major outcome of the process Literatures on different coating process and its observation.

control is in the form of microstructure, adherence, suitability and S. Author Coating Observation
durability. The benefit of the coating process is to reduce the man- No name process
ufacturing cost since the fabrication or replacement of components 1 Habib et al Flame The additions of titania in the coatings
is high. Coating material offers protection to the surface from cor- spray enhance the properties like toughness,
rosion and wear [9]. process porosity and intergranular precipitation
2 Rico et al Plasma Nanostructured coatings provide good wear
The coating process for high-temperature application is carried spray resistance when compared with the
out by two different approaches [10]. The classification of coatings process conventional coatings
is 3 Ibrahim Plasma The presence of partially melted in
et al spray nanostructured coatings act as a crack
process arrest, higher hardness and wear resistance
1. Diffusion coating process
4 Yourong HVOF The HVOF process has extraordinary
2. Overlay coating process Liu et al process deposition of alumina and titania coatings
5 Yilmazet al Plasma Dense and uniform coating has obtained on
Diffusion coating process is the hot section of the component spray the substrate and hardness of the coat is
can be coated by the diffusion coating process. In this process, process higher in a bond coat.
6 Che et al Plasma The roughness of the bond coat has affected
the component can be coated by various techniques like pack-
spray the life of the coatings. By increasing the
cemetation, out-of-pack, gas and vapour phase chemical vapour process bond roughness, lifetime decrease
[11]. Aluminum and chromium or aluminium and silicon are used exponentially
in the diffusion coating process. By adding of reactive elements (Y, 7 Mahesh HVOF The coated material was found effective
et al process oxidation resistance in the temperature of
Hf, Zr) in the modified aluminide has found that oxidation resis-
about 900 °C due to the protective layer
tance has been improved [12]. formed on the surface its enhance to protect
In the overlay process material is deposited on the surface of the the material form material degradation
material [13]. The main objective for the coating process to protect 8 Haynes Plasma No spallation of the ceramic topcoat
the surface and poor oxidation resistance of the base alloy (alu- et al spray occurred up to 200 h during isothermal
process expansion
minide, Pt-aluminide, and MCrAlY). The thermal barrier coatings
9 Tolpygo EB-PVD The oxidation rate of the bond coat affects
(TBCs) which are ceramic coatings it has less thermal conductivity et al process the durability of TBC and cause of TBC
and it’s widely used for high-temperature application. The purpose failure mostly depends on the factors like
of the coatings is to protect the material from the surface degrada- elastic strain energy stored in scale.
10 M. Wen EB-PVD The rumpling and TGO stress relaxation
tion. The different coating processes with the characteristic are
et al rate increase while the specimen life
given in Table 1.1 [6–8]. decreases as cycling temperature increases.
The rumpling effect plays a crucial role in
3. Coatings process affecting the coatings.
11 E.P. Busso Plasma There is a strong correlation between the
et al spray between the local stress and the thickness
3.1. Thermal barrier coatings process of thermally grown oxides. At room
temperature the critical thickness of TGO is
In engineering application, TBCs were carried out to enhance in order of 3 mm.
12 R. Taylor Plasma The authors provide the relationship
the efficiency and to improve the components life. TBCs are widely
et al spray between the microstructure and the
used for two main important functions with two layers (i) ceramic process properties of the coatings. Also made an
top coat- to act as insulator and (ii) metallic bond coat- to prevent attempt to optimize the plasma spray
the material from oxidation and corrosion. In the current research, coatings.
double layer (top coat and bond coat) requires dropping to single 13 W.R. Chen Plasma The formation of TGOs exhibits three
spray stages, the thermal cracking reduced by the
composite or ceramic coatings, especially used to spray on high- process TGO growth, the power law relation holds
temperature material. The TBCs enhances to reduce the surface good for crack length and TGO thickness.
temperature from (100 °C to 300 °C) of superalloy material [14]. 14 A. Rabiei Plasma During less exposure of heat the TGO
In the working environment, the material is possible to undergo spray thickness is less and dosen’t affects crack
process patterns. As TGO thickness increases, cracks
thermal fatigue, it can be minimized with TBCs. The material used
and delamination within TGO and interface.
for high-temperature application should have higher inherent tem- 15 R. Vaßen Plasma Developed Finite element model to predict
perature capabilities, better oxidation and corrosion resistance spray thermal stress in TBC, the result used to
(Table 2). process develop crack propagation model to
estimate crack development.

3.2. Anatomy of a TBC

1. Topcoat
The four-layer depicted in Fig. 2 has a dissimilar combination of 2. Bond coat
materials in layer to enhance properties and their functions. The 3. Substrate
layers are 4. Thermally Grown Oxide (TGO)

Table 1.1
Coating process and their characteristics.

S. No Coating methods Coating thickness Materials Features

1 PVD 1–5 mm Ti(C,N) Wear resistance
2 CVD 1–50 mm SiC Wear resistance
3 Thermal Spray 40–3000 mm Ceramic and metallic alloys Wear and corrosion resistance
4 Hard chromium Plate 10–100 mm Chrome Wear resistance
5 Weld overlay 500–5000 mm Ni based alloys Wear resistance

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D. Chellaganesh, M. Adam Khan and J.T. Winowlin Jappes
Fig. 2. Schematic illustrations of TBCs for turbine blades.
3.3. Topcoat
The topcoat acts as a thermal barrier and is usually made of
Yttria stabilized Zirconia (YSZ). The YSZ preeminent selection is
for the bond coat. Among the other ceramics, YSZ has act as a ther-
mal barrier layer to isolate bond coating from operating tempera-
ture [15].
3.4. Bond coat
The bond coat layer depth has varied from 75 to 150 mm and it
is essential to dictate the spallation failure of TBC. The NiCrAlY or
NiCoCrAlY are used as the bond coat and it is coated using plasma
spray technique, electron beam technique or physical vapour
deposition method. On some occasions to enhance the properties,
the bond coat has multiple layers having dissimilar chemical/phase
composition (Fig. 3).
3.5. Substrate material
The substrates are in combination of nickel, nickel-iron, nickel-
cobalt and soon. These alloys developed to form single crystal
structural components with different alloy elements. It has added
to enhance the specific mechanical and surface properties such
as strength, ductility, oxidation resistance and corrosion resistance
at elevated temperature.
Fig. 3. Delamination of the coated samples during high temperature exposure.
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Materials Today: Proceedings 45 (2021) 1529–1534
3.6. Thermally grown oxide (TGO)
The intermediate oxide scale to a thickness of 10 to 20 mm
below the top coat exposed to elevated temperature called ther-
mally grown oxide (TGO). The layer has formed when the operat-
ing temperature of the turbine has exceeded about 700 °C. TGO
formed in as a-Al2O3 and that it grows slowly, evenly and flawless.
Such TGO has minimum oxygen ionic diffusivity and prevents fur-
ther diffusion by which slow down additional bond coat oxidation
[15]. The bond coat made of improved aluminide alloy such as
MCrAlY (or in any Ni combination) assists to shield the substrate
material from the corrosive environment [16]. During the high
temperature operations the surface of the material started to
degrade at operating temperature of about 600 °C. This might
due to the formation of continuous and dense oxide scale provides
a protective barrier to further oxidation on the surface. The discon-
tinuities resulting from different effect cause the fresh metal to be
non-protective against the oxidising environment which leads to a
high oxidation rate. The high oxidation in the material increases
the temperature of the surface, which helps to enhance the further
increase in the reaction rate.
3.7. Flame-spray process
This process is one of the oldest technologies in thermal spray
method. The capital investment is low, high deposition rates, effi-
ciency is high, ease of operation and maintenance. Gases used for
the process like acetylene, propane, methyl-acetylene-
propardiene, hydrogen along with oxygen are used for flame spray
gases. Flame spray process is a manual operating process carried. It
is widely used for corrosion protection application [17].
3.8. Thermal spray process
Thermal spray process is rapidly growing in the field of surface
engineering. The melted coating materials are sprayed onto a
cleaned surface area at high speed. The coating material may be
in the form of powder, rod and wire [18]. The coating thickness
depends on the application and operating environment. The coat-
ing thickness can be varied from micron level to millimetres. The
thermal barrier coatings are commonly applied to protect the
material from erosion, high-temperature oxidation and hot corro-
sion resistance [19].
3.9. Wire arc spray
In this process, two metal wires are fed independently into the
gun. Based on the power source wires are charged and an arc is
generated between them. Heat source helpful to melt the wire
and molten feedstock are deposited on to a substrate with the help
of compressed air [20,21]. The process is energy efficient entire
input of all heat sources is helpful to melt the metal.
3.10. High-velocity oxy-fuel spray (HVOF)
HVOF process is a recently invented process in the 1980s by
Browing and witfield and rocket engine technology has adapted
for the coating process. For coating process used as oxygen with
one of fuel such as hydrogen, propane, propylene and kerosene.
In this process, the powder particles melt entirely or partially,
depending on the flame temperature, melting point and thermal
conductivity [22].
D. Chellaganesh, M. Adam Khan and J.T. Winowlin Jappes
3.11. Plasma spray
Plasma spray process is one of the most comfortable process
and versatile methods in thermal spray techniques. DC electric
arc source is used to generate steam of highly ionized plasma
gas, which acts as spraying source [23]. The gas flowing in between
the electrodes and it got ionized such that a plasma plume of
length developed in order of several centimetres. The temperature
plume can reach about 16,500 °C. Power levels in this process are
maintained in the range of 30 kW to 80 kW, but some case they
can use upto the level of 120 kW. Argon is usually chosen for base
gas because it is chemically inert and having excellent ionization
characteristic.
The plasma spray technique is used for metallic and non-
metallic materials. The coating material is injected into the plasma
jet in the form of powder and flow is metered employing carrier
gas. The powder particle is heated in the plasma jet and is melted
as molten droplets. Then drops are accelerated in high velocity
which strikes the substrate and adheres on the surface [24]. The
density of the coating typically higher in the range of 80% to 95%
of theoretically. Coating thickness obtained by this process can
be varied from 0.05 to 0.50 mm (0.002 to 0.020 in.). But in some
application, the thickness may be vary based on the operating con-
dition. Bond strength obtained by this process varies from 34 MPa
to 69 MPa [25]. In plasma coating, the particle velocity may vary
from 100 and 500 m/s. The particles are fused completely or par-
tially to deposit on the surface for uniform thickness. The proper-
ties of the coating are controlled by using the optimum coating
process parameters [26].
Thermal spray process is carried out at the inert atmosphere or
lower pressure chamber. Its widely accepted for the aircraft indus-
try. When the plasma gas is heated by the arc, it expands and made
to accelerate through a shaped nozzle (upto mach number 2). The
temperature in the arc zone is about 36,000°F (20,000°K). For cre-
ating the plasma source with argon it requires huge power of about
800 to 100 amps. The high power source has been used to increase
the particle and also to fuse the coating powder. It has been proven
that the plasma spray technique was effective applied hot corro-
sion resistance coating in aircraft engine [27].
The main advantages of the plasma coating process are
(i) Temperature of the substrate can be maintained as 50 °C
(ii) Thickness of coating can be varied from microns to a
millimetre
(iii) Coating process is fast
(iv) No restriction in size and shape
(v) Mechanical and metallurgical bonding can be obtained [28]
4. Conclusion
The review of latest literatures in the domain of TBCs through
various coating methodologies was studied. This work represents
the need for the surface protection in the engineering fields to pro-
tect the surface degradation during the high temperature working
environment. The material and the thickness of each coating
methodologies was discussed. The lucidity on the process of TGO
formation by the various authors provides the importance of thick-
ness of TGO in degradation of the surface material. To utilize the
full potential future research must focus on the understanding
the coating process and its working environment as most impor-
tant one. Based on the review the following conclusions were made
1. TBC protect the component by which enhances the life of the
component during the high temperature exposure.
2. TBC utilizes various methodologies for coating process but
preferably most authors utilize spray coatings.
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Materials Today: Proceedings 45 (2021) 1529–1534
3. TBC mostly done using ceramic materials for the properties. (i.e.
Low thermal conductivity, High corrosion, wear resistance.)
4. The mathematical model between the thickness of TGO and the
crack length follow the pattern of power law.
CRediT authorship contribution statement
D Chellaganesh: Conceptualization, Data curation, Formal anal-
ysis, Investigation, Methodology, Writing - original draft. M. Adam
Khan: Conceptualization, Formal analysis, Methodology, Project
administration, Software, Supervision, Validation, Visualization,
Writing - review & editing. J.T. Winowlin Jappes: Funding acquisi-
tion, Project administration, Resources, Supervision, Visualization.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
Acknowledgements
All persons who have made substantial contributions to the
work reported in the manuscript (e.g., technical help, writing and
editing assistance, general support), but who do not meet the cri-
teria for authorship, are named in the Acknowledgements and have
given us their written permission to be named. If we have not
included an Acknowledgements, then that indicates that we have
not received substantial contributions from non-authors.
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Materials Today: Proceedings 45 (2021) 1529–1534
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