The evolution of thermal barrier coatings — status and upcoming solutions for today’s key issues

Thermal barrier coating applications have been utilized for decades on components subjected to high thermal loads within combustion processes. This paper aims to review the advancements in thermal barrier coatings, focusing particularly on the evolution of electron beam physical vapor deposition (EB-PVD) technology and its implications in enhancing reliability and performance. A comparative analysis of EB-PVD coatings versus plasma-sprayed coatings reveals that while the former exhibits higher thermal conductivity, it also offers a longer lifespan and improved reliability, especially for high-pressure turbine parts. The major challenges hindering the complete integration of thermal barrier technology as a primary design feature have been identified, namely the need for a deeper understanding of failure mechanisms and the rigorous validation of developed life-models through testing and actual component performance. The paper discusses various potential solutions aimed at addressing current technical challenges and advancing TBC applications to achieve higher reliability across diverse engine environments. Considerations include a novel inline hardware concept which combines traditional process sequences with enhanced quality aspects and optimized throughput setups.