Extreme Materials

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Ceramic-based abradable sealing coatings for advanced aeroengines: Materials design, structural strategies, and multifunctional performance

Leyao Wang, Shuqi Wang, Guoliang Chen, Yongchun Zou, Shuang Yu, Enyu Xie, Qingyuan Zhao, Zhiyun Ye, Jiahu Ouyang, Yaming Wang, Dechang Jia, Yu Zhou

Extreme Materials, 2025, 1(4): 33-58. DOI: 10.1016/j.exm.2025.08.003

Performance Indicator	Functional Role	Enhancement Strategy	Negative Impacts
Abradability	Maintains blade-clearance control and avoids blade damage	Reduce hardness and increase porosity	May decrease bonding strength and erosion resistance
Erosion Resistance	Withstands high-speed particle impact	Increase surface hardness	May lead to increased blade wear and reduced abradability
Thermal Shock Resistance	Resists rapid temperature fluctuations, extends service life	Increase porosity and/or introduce nanostructures	May reduce mechanical strength
Corrosion Resistance	Resists water vapor and CMAS (calcium-magnesium-alumino-silicate) corrosion	Employ corrosion-resistant ceramic phases	Often associated with higher hardness or thermal stress
Bonding Strength	Enhances the durability of multilayer structures and prevents delamination	Surface texturing or bonding phase design	Risk of bonding phase oxidation or thermal stress accumulation

Table 3 Contradictions among key performance indicators of coatings.

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Fig. 1. Changes in rotor-stator clearance due to frictional wear [10,11] : (a) initial clearance between stationary and rotating components, (b) rub caused by rotor shaft bending, and (c) post-rub clearance configuration.
Fig. 2. A review of composition and structural design strategies for ceramic-based ASCs.
Fig. 3. Thermal shock life of ceramic ASCs as a function of their porosity[10].
Table 1 Regulation of coating porosity and microhardness [37].
Fig. 4. (a) Schematic illustration and (b) cross-section SEM image of Si/ YbDS EBC system applied to an α-SiC substrate [41,42].
Fig. 5. CMAS corrosion failure mechanism of EBCs [47].
Table 2 Comparison of key performance indicators of coating materials for ASCs.
Table 4 Influence of manufacturing process parameters on coatings microstructure and properties[20].
Fig. 6. SEM images of (a) hollow spherical powder particles [59] and (b) radially porous powder particles [60].
Table 5 Comparison of fabrication methods for nanocomposite coatings.
Fig. 7. SEM images of (a) APS coating (C-YSZ) and (b) SPPS coating (M-YSZ) [64].
Table 6 Comparison of lubricating phase materials for high-temperature coatings.
Fig. 8. SEM images of ZrO₂-coated (a) h- BN particles [71], (b) CaF₂ particles [73].
Table 7 The functions of different binding phases[80].
Fig. 9. The diagram of (a) knee articulation and (b) YSZ-based ASC with an articulation mimicking structure [84].
Fig. 10. Schematic diagram of the self-healing mechanism of porous LMA-based ASCs and CMAS corrosion behavior [88].
Table 8 CTEs of the constituent phases in the HfO₂-Si bond coat.
Fig. 11. Structural schematics of (a) A/EBC [33] and (b) gradient A/EBC [48].
Fig. 12. Schematic illustration of the single-layer 75YbDS-25YbMS, 25YbDS-75YbMS, and gradient EBC after water vapor corrosion [102].
Fig. 13. Surface micro-textures for enhanced coating adhesion: SEM and schematic representations. (a) Random micro-texture pattern;(b) Regular circular pore array;(c) Inclined hole texture;(d) Hexagonal texture array;(e) Schematic of multi-scale hierarchical bioinspired structure;(f) Comparative schematic of bioinspired micro-texture versus grit-blasted substrate with top coating;(g) Square-grid micro-texture schematic. [116,115,118].
Fig. 14. Typical wear map of ceramic-based ASCs [128].
Fig. 15. Wear mechanism model of ceramic-based ASCs [130].
Table 9 Domestic evaluation methods for the abradability of seal coatings.
Fig. 16. Schematic diagram of the abradability test rig[134].
Table 10 The abradability performance of several typical ceramic-based ASCs.
Fig. 17. Schematic diagram of the erosion test apparatus [139].
Fig. 18. Schematic diagram of the water vapor corrosion testing apparatus [149].

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