Thermoelastic characteristics of thermal barrier coatings with layer thickness and edge conditions through mathematical analysis.

The thermoelastic behaviors of such as temperature distribution, displacements, and stresses in thermal barrier coatings (TBCs) are seriously influenced by top coat thickness and edge conditions, which were investigated based on the thermal and mechanical properties of plasma-sprayed TBCs. A couple of governing partial differential equations were derived based on the thermoelastic theory. Since the governing equations are too involved to solve analytically, a finite volume method was developed to obtain approximations. The thermoelastic characteristics of TBCs with the various thicknesses and microstructures were estimated through mathematical approaches with different edge conditions. The results demonstrated that the top coat thickness and the edge condition in theoretical analysis are crucial factors to be considered in controlling the thermoelastic characteristics of plasma-sprayed TBCs.

Thermal Fatigue Behavior of Air-Plasma Sprayed Thermal Barrier Coating with Bond Coat Species in Cyclic Thermal Exposure.

The effects of the bond coat species on the delamination or fracture behavior in thermal barrier coatings (TBCs) was investigated using the yclic thermal fatigue and thermal-shock tests. The interface microstructures of each TBC showed a good condition without cracking or delamination after flame thermal fatigue (FTF) for 1429 cycles. The TBC with the bond coat prepared by the air-plasma spray (APS) method showed a good condition at the interface between the top and bond coats after cyclic furnace thermal fatigue (CFTF) for 1429 cycles, whereas the TBCs with the bond coats prepared by the high-velocity oxygen fuel (HVOF) and low-pressure plasma spray (LPPS) methods showed a partial cracking (and/or delamination) and a delamination after 780 cycles, respectively. The TBCs with the bond coats prepared by the APS, HVOF and LPPS methods were fully delaminated (>50%) after 159, 36, and 46 cycles, respectively, during the thermal-shock tests. The TGO thickness in the TBCs was strongly dependent on the both exposure time and temperature difference tested. The hardness values were found to be increased only after the CFTF, and the TBC with the bond coat prepared by the APS showed the highest adhesive strength before and after the FTF.