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The lifespan and performance of the industrial components used in aero engine’s and IC engines can be considerably increased by depositing thermal barrier coatings (TBCs). High-pressure gas turbines’ rotor blades and stator vanes are some of the world’s most heavily loaded engineering parts. In order to safeguard such components, more research is being conducted on TBCs, since the size of deployment and the production techniques used lead to improved life, economics, efficiency, and durability. This paper concentrates on the technological developments in the field of TBCs over the past few years in order to achieve maximum output. Current coating R&D has also placed an emphasis on the factors that contributed to the development of cutting-edge advanced coating-fabrication techniques, such as electron-beam physical vapor deposition (EB-PVD), suspension plasma spray (SPS), additive manufacturing (AM), functionally graded material (FGM) and incorporation of artificial intelligence (AI) in manufacturing of TBCs. This paper examines the current state of TBCs, including the most recent developments in terms of their performance and manufacturing, associated challenges, and suggestions for their potential usage in high temperature sector.

The pure iron and aluminum powders were milled with 3wt.% and 7wt.% of alumina nanoparticles in planetary ball mill in order to produce iron aluminide by mechanical alloying technique. The resulting powder mixture was sintered after the formation of iron aluminide by spark plasma sintering (SPS) method to achieve specimens with the highest densification. SPS technique was utilized on specimens under the condition of 40MPa pressure at 950^∘C for 5min. The microstructures were analyzed after sintering using scanning electron microscopy and EDS analysis. The results indicated that the aluminide iron phase has been produced at high purity. The sintered specimens were treated under hardness and density tests, and it was characterized that the specimen included 3wt.% of alumina nanoparticles had the highest microhardness. Likewise, it was revealed that the unreinforced sample had a maximum relative density. The wear behavior of specimens was performed at 600^∘C. The results of weight loss showed after 1000m of wear test, the weight loss of unreinforced specimen was reduced up to 0.21g while the specimen with 3wt.% of alumina nanoparticle indicated the lowest weight loss about 0.02g. The worn surfaces were evaluated by scanning electron microscopy which indicated that the main wear mechanism at high temperature included adhesive wear and delamination.