To achieve a higher efficiency in gas turbine engine by increasing the inlet-temperature of burning gas is one of the primary goals in aviation industry. The development of thermal barrier coating system (TBCs) continuously raises the inlet-temperature of gas turbine engine in the past decades. Due to the complexity of TBCs and harsh operation environments, the degradation and failure mechanisms of hot section components have not been fully understood, and consequently limits the application of TBCs. It was identified that high-temperature sintering of the topcoat in a typical TBC could be one of the major sources of its failure since the microstructures of the constituent coating layers evolve dynamically during the service period, resulting in significant changes of mechanical and thermal physical properties of the coating system. This paper intends to review recent advances of analytical and numerical modeling of sintering of topcoat in TBCs including the modeling methodology and applications of the models, particularly the implementation of finite element combined with specific materials constitutive functions. Critical remarks on the future development and applications of these models are also discussed in the end.

Solid particle erosion (SPE) is a common phenomenon observed in gas turbine engines. Particles entrained in the gas flow impact engine hardware, resulting in micro-scale damage that leads to deleterious effects such as material removal. For protective coatings, damage due to SPE is a key concern, since it can negatively affect the durability of the coating and subsequently the life of the underlying component. In this work, the high-temperature SPE behavior of two state-of-the-art environmental barrier coatings (EBCs) deposited via air plasma spray (APS) is investigated using alumina erodent to understand the effect of particle kinetic energy, impingement angle, and temperature. The SPE behavior of the EBCs is also compared to APS and electron beam–physical vapor deposition (EB-PVD) thermal barrier coatings (TBCs) to elucidate similarities and differences in the erosion response. The EBCs were more susceptible to SPE than the EB-PVD TBC but had greater SPE resistance compared to the APS TBC. Coating microstructure and porosity were shown to have a strong influence on the observed behavior.

The global increase in air travel will require commercial vehicles to be more efficient than ever before. Advanced turbine hot section materials are a key technology required to keep fuel consumption and emission to a minimum. Ceramic matrix composites (CMCs) are the most promising material to revolutionize turbine hot section materials because of their excellent high-temperature properties. Rapid surface recession due to volatilization by water vapor is the Achilles heel of CMCs. Environmental barrier coatings (EBCs), which protect CMCs from water vapor, is an enabling technology for CMCs. The first CMC component entered into service in 2016 in a commercial engine, and more CMC components are scheduled to follow within the next few years. One of the most difficult challenges to CMC components is EBC durability because failure of EBC leads to a rapid reduction in CMC component life. Novel EBC chemistries, creative EBC designs, and robust processes are required to meet EBC durability challenges. Engine-relevant testing, characterization, and lifting methods need to be developed to improve EBC reliability. The aim of this Special Issue is to present recent advances in EBC technology to address current EBC challenges.