Thermal Barrier Coating in Aviation Maintenance and Upkeep


A thermalbarrier coating (TBC) is a highly advanced system applied to surfaces, like metals, especially in aviation engine and gas turbine parts that operate at extremely high temperatures. It performs well in managing exhaust heat. These are advanced materials used as coatings on turbines or aircraft engines for materials protection against excessive heat in high-temperature processes. Typical oxides used as TBCs include yttria-stabilized zirconia. Typical failure occurs due to thermal fatigue, accelerated oxidation, hot corrosion or molten deposit degradation. There is a need for TBCs that can withstand higher temperature during extended periods of time.

Structural components of TBCs
A thermalbarrier coating is designed to protect metal structural components from extreme elevated temperatures, thereby reducing stress and fatigue and increasing the part’s lifespan. In order to provide such a high level of protection, thermal barriers incorporate several key components. Every coating consists of four distinct layers, with each layer adding to the protective thermal properties and enabling the coating to form a unique thermal barrier.

TBCs contain four main layers: metallic bond coat, metal substrate, ceramic top coat, and oxide grown thermally. Typically, the ceramic top coat is composed of yttria stabilized zirconia (YSZ), which is known for its low conductivity and stability under nominal temperatures for operation. Alternatives to YSZ have been created, but ceramic top coats with YSZ are relatively tougher and can deliver better performance.

A thermalbarrier coating can be used in various industrial and automotive settings. For instance, TBCs can be used to lessen heat loss from the exhaust system of automobile engines which may include turbochargers, tailpipes, downpipes, exhaust manifolds, and other components.

Usage of TBCs as insulators in high-heat exposures
Such coatings can serve as insulators, especially in components that are often exposed to prolonged heating. This type of coating can accommodate higher temperatures during operation and at the same time, limit thermal exposure of other structures. It can prolong the life of parts and other structures by decreasing thermal fatigue and oxidation.

Though this type of coating can be applied straight to metal parts, advanced technology allows TBC application on composite materials. Due to this, TBC coating is often used in high-performance vehicles like Formula 1. Apart from providing thermal protection, it can be used in preventing degradation due to friction. The role of TBC is to prevent melting, promoting high gas temperature inlets, which leads to more efficient energy conversion. While this is the case, the surface must be prepared thoroughly before coating with TBC to achieve the best results.

TBC is an excellent solution for the majority of exhaust related applications.  However, for extreme performance applications, the thermal barrier coatings can also be applied by the plasma spraying process, producing coatings that are denser and with higher bond strengths than with powder flame spray.


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