Understanding the Failure Mechanism of Thermal Barrier Coatings Considering the Local Bulge at the Interface between YSZ Ceramic and Bond Layer

The TC/BC interface morphology in APS TBC is one of the important factors leading to crack propagation and coating failure. Long cracks are found near the bulge on the TC/BC interface. In this study, the TBC model with the bulge on the interface is developed to explore the influence of the bulge on the coating failure. Dynamic TGO growth and crack propagation are considered in the model. The effects of the bulge on the stress state and crack propagation in the ceramic layer are examined. Moreover, the effects of the distribution and number of bulges are also investigated. The results show that the bulge on the interface results in the redistribution of local stress. The early cracking of the ceramic layer occurs near the top of the bulge. One bulge near the peak or valley of the interface leads to a coating life reduction of about 75% compared with that without a bulge. The increase in the number of bulges further decreases the coating life, which is independent of the bulge location. The results in this work indicate that a smooth TC/BC interface obtained by some possible surface treatments may be an optional scenario for improving coating life.

Columnar-structured thermal barrier coatings deposited via the water-based suspension plasma spray process

Suspension plasma spray (SPS) has been developed to be a rapid, facile and cost-effective process to deposit columnar-structured thermal barrier coatings (TBCs). Different than the most commonly used ethanol-based suspensions, water-based suspensions have not been used in the SPS process to deposit columnar-structured TBCs due to their high surface tension, although they are much cheaper and safer. In this work, a new water-based SPS process was prepared by adding surfactant to lower the surface tension. The optimum content of dispersant and surfactant added into the suspension was determined via the measurements of viscosity, particle size, surface tension, contact angles, and atomized droplet size. Coatings deposited using suspension with and without surfactant showed typical columnar-structured microstructures and vertically-cracked microstructures, respectively. The coatings deposited using suspension with surfactant also showed an evolution from columnar-structured microstructures to mixed microstructures of columns and cracks, and to homogeneous microstructures with the increase of standoff distance. The formation of different coating microstructures were correlated to the size of droplets after aerodynamic breakup and the Stokes number of in-flight particles. The new water-based suspension together with the water-based SPS process show high potential to be a cheap and effective alternative to the ethanol-based SPS process.