Thermal Barrier Coatings: A concise review on Materials and Mechanisms

Thermal Barrier Coatings (TBCs) are pivotal in safeguarding high-temperature components in aerospace and energy applications. This paper explores the structural composition of TBC systems, including substrate, bond coat, thermally grown oxide (TGO) layer, and ceramic topcoat. Various deposition techniques such as Atmospheric Plasma Spraying (APS) and Electron Beam Physical Vapor Deposition (EB-PVD) are discussed for their impact on coating performance. Challenges such as crack propagation, thermal fatigue, and environmental degradation are analysed to understand their influence on TBC longevity. Notably, the potential of advanced materials, including rare earth zirconates and hafnium-based ceramics, is evaluated to enhance thermal stability and damage tolerance. The ongoing research aims to mitigate existing limitations while pushing the boundaries of TBC technology in high-temperature applications, ensuring improved performance and efficiency