Multiscale Pores in TBCs for Lower Thermal Conductivity

The morphology and pattern (including orientation and aspect ratio) of pores in thermal barrier coatings (TBCs) significantly affect their thermal insulation performance. In this work, finite element analysis was used to comprehensively understand the thermal insulation effect of pores and correlate the effective thermal conductivity with the structure. The results indicated that intersplat pores, and in particular their aspect ratio, dominantly affect the heat transfer in the top coat. The effective thermal conductivity decreased as a function of aspect ratio, since a larger aspect ratio often corresponds to a greater proportion of effective length of the pores. However, in conventional plasma-sprayed TBCs, intersplat pores often fail to maximize thermal insulation due to their distinct lower aspect ratios. Therefore, considering this effect of aspect ratio, a new structure design with multiscale pores is proposed and a corresponding structural model developed to correlate the thermal properties with this pore-rich structure. The predictions of the model are well consistent with experimental data. This study provides comprehensive understanding of the effect of pores on the thermal insulation performance, shedding light on the possibility of structural tailoring to obtain advanced TBCs with lower thermal conductivity.