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Suspension plasma spray coating of advanced ceramics : thermal barrier applications
\"Suspension Plasma Spray Coating of Advanced Ceramics presents the significance of suspension plasma spray coating of ceramics for thermal barrier applications. It covers suspension formation and optimization in different oxide and non-oxide mixtures and ceramic matrix composites (CMC) of sub-micron and nanosized powders. The book will be useful for professional engineers working in surface modification and researchers studying materials science. This book discusses advanced topics on nanomaterials coatings in monolithic or composite forms as thermal barriers through organic and non-organic based suspensions using high energy plasma spray methods\"-- Provided by publisher.
Book
Progress in ceramic materials and structure design toward advanced thermal barrier coatings
Thermal barrier coatings (TBCs) can effectively protect the alloy substrate of hot components in aeroengines or land-based gas turbines by the thermal insulation and corrosion/erosion resistance of the ceramic top coat. However, the continuous pursuit of a higher operating temperature leads to degradation, delamination, and premature failure of the top coat. Both new ceramic materials and new coating structures must be developed to meet the demand for future advanced TBC systems. In this paper, the latest progress of some new ceramic materials is first reviewed. Then, a comprehensive spalling mechanism of the ceramic top coat is summarized to understand the dependence of lifetime on various factors such as oxidation scale growth, ceramic sintering, erosion, and calcium-magnesium-aluminium-silicate (CMAS) molten salt corrosion. Finally, new structural design methods for high-performance TBCs are discussed from the perspectives of lamellar, columnar, and nanostructure inclusions. The latest developments of ceramic top coat will be presented in terms of material selection, structural design, and failure mechanism, and the comprehensive guidance will be provided for the development of next-generation advanced TBCs with higher temperature resistance, better thermal insulation, and longer lifetime.
Journal Article
Elucidating the role of preferential oxidation during ablation: Insights on the design and optimization of multicomponent ultra-high temperature ceramics
Multicomponent ultra-high temperature ceramics (UHTCs) are promising candidates for thermal protection materials (TPMs) used in aerospace field. However, finding out desirable compositions from an enormous number of possible compositions remains challenging. Here, through elucidating the role of preferential oxidation in ablation behavior of multicomponent UHTCs via the thermodynamic analysis and experimental verification, the correlation between the composition and ablation performance of multicomponent UHTCs was revealed from the aspect of thermodynamics. We found that the metal components in UHTCs can be thermodynamically divided into preferentially oxidized component (denoted as
M
P
), which builds up a skeleton in oxide layer, and laggingly oxidized component (denoted as
M
L
), which fills the oxide skeleton. Meanwhile, a thermodynamically driven gradient in the concentration of
M
P
and
M
L
forms in the oxide layer. Based on these findings, a strategy for pre-evaluating the ablation performance of multicomponent UHTCs was developed, which provides a preliminary basis for the composition design of multicomponent UHTCs.
Journal Article
Air plasma-sprayed high-entropy (Y0.2Yb0.2Lu0.2Eu0.2Er0.2)3Al5O12 coating with high thermal protection performance
High-entropy rare-earth aluminate (Y
0.2
Yb
0.2
Lu
0.2
Eu
0.2
Er
0.2
)
3
Al
5
O
12
(HE-RE
3
Al
5
O
12
) has been considered as a promising thermal protection coating (TPC) material based on its low thermal conductivity and close thermal expansion coefficient to that of Al
2
O
3
. However, such a coating has not been experimentally prepared, and its thermal protection performance has not been evaluated. To prove the feasibility of utilizing HE-RE
3
Al
5
O
12
as a TPC, HE-RE
3
Al
5
O
12
coating was deposited on a nickelbased superalloy for the first time using the atmospheric plasma spraying technique. The stability, surface, and cross-sectional morphologies, as well as the fracture surface of the HE-RE
3
Al
5
O
12
coating were investigated, and the thermal shock resistance was evaluated using the oxyacetylene flame test. The results show that the HE-RE
3
Al
5
O
12
coating can remain intact after 50 cycles at 1200 °C for 200 s, while the edge peeling phenomenon occurs after 10 cycles at 1400 °C for 200 s. This study clearly demonstrates that HE-RE
3
Al
5
O
12
coating is effective for protecting the nickel-based superalloy, and the atmospheric plasma spraying is a suitable method for preparing this kind of coatings.
Journal Article
Review of Ceramic Composites in Aeronautics and Aerospace: A Multifunctional Approach for TPS, TBC and DBD Applications
The quest for increased performance in the aeronautical and aerospace industries has provided the driving force and motivation for the research, investigation, and development of advanced ceramics. Special emphasis is therefore attributed to the ability of fine ceramics to fulfill an attractive, extreme, and distinguishing combination of application requirements. This is impelled by ensuring a suitable arrangement of thermomechanical, thermoelectric, and electromechanical properties. As a result, the reliability, durability, and useful lifetime extension of a critical structure or system are expected. In this context, engineered ceramic appliances consist of three main purposes in aeronautical and aerospace fields: thermal protection systems (TPS), thermal protection barriers (TBC), and dielectric barrier discharge (DBD) plasma actuators. Consequently, this research provides an extensive discussion and review of the referred applications, i.e., TPS, TBC, and DBD, and discusses the concept of multifunctional advanced ceramics for future engineering needs and perspectives.
Journal Article
Oxidation-based materials selection for 2000°C + hypersonic aerosurfaces: Theoretical considerations and historical experience
Hypersonic flight involves extremely high velocities and gas temperatures with the attendant necessity for thermal protection systems (TPS). New high temperature materials are needed for these TPS systems. A systematic investigation of the thermodynamics of potential materials revealed that low oxidation rate materials, which form pure scales of SiO2, Al2O3, Cr2O3, or BeO, cannot be utilized at temperatures of 1800°C (and above) due to disruptively high vapor pressures which arise at the interface of the base material and the scale. Vapor pressure considerations provide significant insight into the relatively good oxidation resistance of ZrB2- and HfB2-based materials at 2000°C and above. These materials form multi-oxide scales composed of a refractory crystalline oxide (skeleton) and a glass component, and this compositional approach is recommended for further development. The oxidation resistance of ZrB2-SiC and other non-oxide materials is improved, to at least 1600°C, by compositional modifications which promote immiscibility in the glass component of the scale. Other candidate materials forming high temperature oxides, such as rare earth compounds, are largely unexplored for high temperature applications and may be attractive candidates for hypersonic TPS materials.
Journal Article
Materials design for hypersonics
Hypersonic vehicles must withstand extreme conditions during flights that exceed five times the speed of sound. These systems have the potential to facilitate rapid access to space, bolster defense capabilities, and create a new paradigm for transcontinental earth-to-earth travel. However, extreme aerothermal environments create significant challenges for vehicle materials and structures. This work addresses the critical need to develop resilient refractory alloys, composites, and ceramics. We will highlight key design principles for critical vehicle areas such as primary structures, thermal protection, and propulsion systems; the role of theory and computation; and strategies for advancing laboratory-scale materials to manufacturable flight-ready components.
Hypersonic vehicles experience extreme temperatures, high heat fluxes, and aggressive oxidizing environments. Here, the authors highlight key materials design principles for critical vehicle areas and strategies for advancing laboratory-scale materials to flight-ready components.
Journal Article
A Selective Review of Ceramic, Glass and Glass–Ceramic Protective Coatings: General Properties and Specific Characteristics for Solar Cell Applications
A review on ceramics, glasses and glass–ceramics as thin film protective coatings for solar cells is given. The different preparation techniques and the physical and chemical properties are presented in a comparative way. This study is useful for technologies involving solar cells and solar panel cell development at the industrial scale, because protective coatings and encapsulation play a major role in increasing the lifetime of solar panels and environmental protection. The aim of this review article is to give a summary of existing ceramic, glass, and glass–ceramic protective coatings and how they apply to solar cell technology: silicon, organic or perovskite cells. Moreover, some of these ceramic, glass or glass–ceramic layers were found to have dual functionality, such as providing anti-reflectivity or scratch resistance to give a two-fold improvement to the lifetime and efficiency of the solar cell.
Journal Article
Review of Lightweight, High-Temperature Thermal Insulation Materials for Aerospace
Lightweight, high-temperature thermal insulation materials play a critical role in aerospace applications, where extreme temperature conditions necessitate lightweight, high-performance solutions. This paper explores advancements in lightweight, high-temperature insulation materials specifically designed for aerospace environments, focusing on innovative flexible ceramic fiber felts, thermal insulation tiles, nano-insulation materials (aerogels), and multilayer insulations (MLIs). These materials exhibit superior thermal resistance, low density, and durability under dynamic and harsh conditions. Key developments include the integration of nanostructures to enhance thermal conductivity control and improve mechanical stability. This paper also highlights applications in spacecraft thermal protection systems, providing insights into the challenges of future material design strategies. These advancements underscore the growing potential of thermal insulations to improve energy efficiency, safety, and performance in aerospace missions.
Journal Article
High Entropy Alloy Coatings and Technology
Recently, the materials research community has seen a great increase in the development of multicomponent alloys, known as high entropy alloys (HEAs) with extraordinary properties and applications. In surface protection and engineering, diverse applications of HEAs are also being counted to benefit from their attractive performances in various environments. Thermally sprayed HEA coatings have outperformed conventional coating materials and have accelerated further advancement in this field. Therefore, this review article overviews the initial developments and outcomes in the field of HEA coatings. The authors have also categorized these HEA coatings in metallic, ceramic, and composite HEA coatings and discussed various developments in each of the categories in detail. Various fabrication strategies, properties, and important applications of these HEAs are highlighted. Further, various issues and future possibilities in this area for coatings development are recommended.
Journal Article