A review on failure mechanism of thermal barrier coatings and strategies to extend their lifetime

Thermal barrier coating (TBC) system is an essential technology in many fields associated to high temperatures. The main function of these TBCs is to protect the metallic parts against high temperatures over 1000 °C. However, degradation occurs both in thermal and mechanical performances during service. Thus, understanding the underlying degradation and failure mechanisms of TBCs is significant to assess and further enhance the durability and reliability of TBCs. Regarding the durability of TBCs, this paper reviews different failures mechanisms of TBCs caused by residual stresses, phase transformations, sintering, hot corrosion attack and oxidation. Subsequently, some methods are summarized to alleviate the undesirable effects of the causes, so as to extend the lifetime of TBCs. Regarding the thermal barrier performance of TBCs, the neoteric advances to resist degradation in thermal conductivity of TBCs are reviewed. In addition, some new ceramic materials with superior intrinsic properties are introduced for ultra-high temperature applications. In brief, this review correlates the microstructure and properties of TBCs for finer interpretation and degradation-resistant design on their thermal and mechanical properties, which would benefit the advanced TBCs in future engineering applications.