High-temperature Corrosion and Protection of Thermal Barrier Coatings for Aeroengines and Gas Turbines

doi:10.11902/1005.4537.2024.227

Journal of Chinese Society for Corrosion and protection

2025, Vol. 45

Issue (1): 1-19 DOI: 10.11902/1005.4537.2024.227

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High-temperature Corrosion and Protection of Thermal Barrier Coatings for Aeroengines and Gas Turbines

WANG Kun¹^,², ZOU Lanxin¹^,², GUO Lei¹^,²(

), YAN Kai³, YE Fuxing¹^,², LIU Hongli⁴, GUO Hongbo⁵(

)

1 School of Materials Science and Engineering, Tianjin University, Tianjin 300072, China
2 Tianjin Key Laboratory of Advanced Joining Technology, Tianjin University, Tianjin 300072, China
3 China Special Equipment Inspection ＆ Research Institute, Beijing 100029, China
4 College of Aeronautical Engineering, Civil Aviation University of China, Tianjin 300300, China
5 School of Materials Science and Engineering, Beihang University, Beijing 100191, China

Cite this article:

WANG Kun, ZOU Lanxin, GUO Lei, YAN Kai, YE Fuxing, LIU Hongli, GUO Hongbo. High-temperature Corrosion and Protection of Thermal Barrier Coatings for Aeroengines and Gas Turbines. Journal of Chinese Society for Corrosion and protection, 2025, 45(1): 1-19.

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Abstract

Thermal barrier coating (TBC) is a critical technology for hot sections of aeroengines and gas turbines. The development of TBC can significantly improve fuel efficiency and thrust-to-weight ratio of engines, allowing them to operate at higher temperatures. However, this has also led to increasingly serious high-temperature corrosion issues for TBC. High-temperature corrosion includes environmental deposition corrosion, namely CaO, MgO, Al₂O₃ and SiO₂ (CMAS) induced corrosion, molten salt corrosion, and the coupling corrosion of CMAS and molten salts, which cause premature failure of TBC and pose a serious threat to the safe operation of aero-engines and gas turbines. This paper reviews the discovery process of these corrosion problems and their reaction mechanisms with TBC at high temperatures, and summarizes the current international research progress on the corrosion-resistant TBC from two aspects, i.e., new TBC materials development and novel coating microstructure design. By comprehensively sorting out the corrosion problems and protection methods of TBC at high temperatures, the paper provides a perspective on the research direction for developing long-lifetime and corrosion-resistant TBC.

Key words: thermal barrier coating CMAS corrosion molten salt corrosion coupling corrosion

Received: 29 July 2024 32134.14.1005.4537.2024.227

ZTFLH:

TG174.4

Fund: National Science and Technology Major Project(J2022-VI-0009-0040);National Natural Science Foundation of China(52272070)

Corresponding Authors: GUO Lei, E-mail: glei028@tju.edu.cn;
GUO Hongbo, E-mail: guo.hongbo@buaa.edu.cn

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	WANG Kun
	ZOU Lanxin
	GUO Lei
	YAN Kai
	YE Fuxing
	LIU Hongli
	GUO Hongbo

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https://www.jcscp.org/EN/10.11902/1005.4537.2024.227 OR https://www.jcscp.org/EN/Y2025/V45/I1/1

Fig.1 Cross-sectional backscattered SEM images of the CMAS glass samples after treatment at 1150 ^oC for 0.5 h (a, b) and 1.5 h (c, d). In Fig.1c, the macro-morphology of the corresponding sample is also provided^[23]

Fig.2 Cross-sectional microstructures of polished (a, b) and as-fabricated (c, d) YSZ bulks exposed to CMAS at 1250 ^oC for 1 h, EDS element mappings of the sample shown in Fig.2d (e)^[36]

Fig.3 Cross-sectional morphology of Ti₂AlC/YSZ coating attacked by CMAS at 1250 ^oC for 2 h (a), corresponding EDS mappings of Al, Ca, Ti and Si (b), and enlarged images (c, d) of the zones 1 and 2 marked in Fig.3a, respectively^[64]

Fig.4 Surface (a) and cross-sectional (b) images of the coating with single laser-glazed layer, and fracture sections of the coatings with single laser-glazed layer (c) and double laser-glazed layers (d)^[90]

Fig.5 Cross-sectional image of Gd₂Zr₂O₇-LaPO₄ coating after hot corrosion in molten V₂O₅ at 900 ^oC for 4 h (a), and enlarged image of the reaction layer (b)^[108]

Fig.6 Macro morphologies (a, c, e) and cross-sectional SEM images (b, d, f) of YSZ pellets exposed to CMAS-V (a, b), CMAS-Cl (c, d) and CMAS-S (e, f) at 1200 ^oC for 0.5 h^[133]

Fig.7 DSC curves of CMAS, CMAS + 5SS and CMAS +10SS powders^[139]

Fig.8 Schematic illustrations of spreading and infiltration of CMAS and CMAS + SS melts on YSZ TBCs^[139]

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