Research Progress on Material and Structure Optimization of Environmental Barrier Coatings

doi:10.11902/1005.4537.2024.283

Journal of Chinese Society for Corrosion and protection

2025, Vol. 45

Issue (1): 33-45 DOI: 10.11902/1005.4537.2024.283

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Research Progress on Material and Structure Optimization of Environmental Barrier Coatings

REN Mingze, DONG Lin(

), YANG Guanjun

State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi'an Jiaotong University, Xi'an 710049, China

Cite this article:

REN Mingze, DONG Lin, YANG Guanjun. Research Progress on Material and Structure Optimization of Environmental Barrier Coatings. Journal of Chinese Society for Corrosion and protection, 2025, 45(1): 33-45.

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Abstract

Environment barrier coatings (EBC) provide effective protection from high-temperature water vapor corrosion for silicon carbide ceramic matrix composites (SiC-CMC), serving as a key material for the next-generation high-temperature components of aircraft engines. This paper reviews the preparation technology and typical structural characteristics for EBC of rare earth silicate/Si bond layer, and discusses the service failure mechanisms in high-temperature engine environments rich in water vapor and deposits CaO-MgO-Al₂O₃-SiO₂ (CMAS). Furthermore, addressing issues such as thermal mismatch of coatings, high-temperature water vapor corrosion, CMAS corrosion, and bond coat oxidation, the design and optimization methods of silicate top coats and Si bond coats are summarized from the perspectives of materials and structures. In response to the demand for even higher operating temperatures, advancements in ultra-high-temperature surface layer structure design and the development of new high-temperature-resistant bond coat materials are introduced. Finally, future research directions for high-performance environment barrier coatings are discussed.

Key words: environmental barrier coatings rare earth silicate thermal spraying corrosion oxidation

Received: 03 September 2024 32134.14.1005.4537.2024.283

ZTFLH:

TG174.4

Fund: National Natural Science Foundation of China(52301102);China Postdoctoral Science Foundation(2024M752571)

Corresponding Authors: DONG Lin, E-mail: donglin@xjtu.edu.cn

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https://www.jcscp.org/EN/10.11902/1005.4537.2024.283 OR https://www.jcscp.org/EN/Y2025/V45/I1/33

Fig.1 Operating temperature prediction and research progress of materials applied in gas turbine engines^[3]

Fig.2 Key performance requirements of EBC materials

Table 1 Thermal parameters of commonly investigated EBC candidate materials^[3,6,9]

Fig.3 Evolution of structure and material of EBC system: (a) the first generation-YSZ/Mullite, (b) the second generation-BSAS/Mullite/Si, (c) the third generation-REMS/Mullite/Si^[20], (d) the third generation-REDS/Si^[21]

Fig.4 Typical structures of EBC obtained via low-temperature fabrication methods: (a, b) electrophoretic deposition-sintering method^[24], (c) suspension immersion coating-sintering method^[25]

Fig.5 Deposition mechanism of thermal spray coatings^[27]

Fig.6 Typical structures of EBC prepared by APS method: (a1, a2) as-sprayed coating, (b1, b2) annealed coating^[29]

Fig.7 Typical structures of EBC prepared by spraying under low pressure: (a) cross section^[34], (b) surface^[35]

Fig.8 Primary failure modes of EBC

Fig.9 Microstructure change of SiO₂-TGO corresponding to its thickening and cracking after 200 h (a), 500 h (b) and 1000 h (c) thermal cycling at 1300 ^oC in air^[39]

Fig.10 Microstructural characteristics of EBC after high-temperature water vapor corrosion^[41]

Fig.11 Influences of temperature and airflow rate on the morphology of EBC during water vapor corrosion: (a) low tem-perature and low flow velocity^[3], (b) low temperature and high flow velocity^[42], (c) high temperature and high flow velocity^[43]

Fig.12 Microstructures of the top layer of EBC after CMAS corrosion: (a) low-magnification image, (b) high-magnification image^[44]

Fig.13 High-temperature CMAS corrosion of EBC: (a) effect of temperature on CaO-AlO_1.5-SiO₂ equilibrium phase diagram^[45],(b) microstructure of YbDS after CMAS corrosion at 1500 ^oC^[46]

Fig.14 Effect of solid solution high entropy on water vapor stability of rare earth silicate^[44]

Fig.15 Microstructures of the top layers of YbDS coatings without (a) and with (b) Al₂O₃ doping after water vapor corrosion^[51]

Fig.16 Morphological characteristics of plasma sprayed Yb₂Si₂O₇ deposits under the pre-heating conditions of room temper-ature (a), 300 ^oC (b) and 600 ^oC (c)^[52]

Fig.17 Microstructures of EBC without (a1, a2) and with (b1, b2) aluminum infiltration densification after water vapor corrosion^[54]

Fig.18 Microstructural characteristic of T/EBC system composed of LMA/LMA-LAS/YbDS/Si multilayers^[55]

Fig.19 Microstructural characteristics of Si-HfO₂ as a novel bonding layer before (a) and after (b) oxidation at 1370 ^oC for 100 h^[59]

Fig.20 Surface microstructures of a novel bonding layer YSi after slow oxidation (a) and rapid oxidation (b) at high temperature^[62]

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