The evolution of microhardness, fracture toughness and residual stress of an air plasma-sprayed thermal barrier coating system under thermal cycles was investigated by a modified Vickers indentation instrument coupled with three kinds of indentation models. The results show that fracture toughness on the top coating surface after thermal cycles changes from 0.64 to 3.67 MPa m 1/2 , and the corresponding residual stress near the indented region varies from − 36.8 to − 243 MPa. For the interface region of coating and bond coat, fracture toughness in the coating close to interface ranges from 0.11 to 0.81 MPa m 1/2 , and residual stress varies from − 5 to − 30 MPa, which are consistent with available data. For the lateral region of coating, fracture toughness and residual stress display strong gradient characteristics along the thickness direction due to the special layered structure.

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Evaluation of microhardness, fracture toughness and residual stress in a thermal barrier coating system: A modified Vickers indentation technique

Influences of interface morphology and thermally grown oxide thickness on residual stress distribution in thermal barrier coating system

A set of aerofoil shaped air plasma sprayed thermal barrier coated (APS-TBC) specimens were adopted in this paper to investigate the stress distributions in the ceramic top coat (TC) and the thermally grown oxide (TGO), the mechanism of local crack generation and propagation at the TC/BC (bond coat) interface. The failure mode of the TBC system, the distribution of asperities at TC/BC interface, thickness of the TC and BC, and the TC microstructure were found to be influenced by substrate curvature. Residual stress was therefore measured across the thickness of the TC, along the undulating TGO and mapped at locations of asperities where failure tended to occur to interpret the initiation of local failure. The role of the TGO was investigated via its chemical bonding with the TC and the decohesion occurring at the TGO/BC interface. The crack propagation at the interface has been discussed with respect to the macro-failure of the TBC system.

Effect of substrate curvature on residual stresses and failure modes of an air plasma sprayed thermal barrier coating system

A set of Ni-based single crystal superalloy aero-blade sections with electron beam physical vapour deposited thermal barrier coating (EBPVD-TBC) were used to investigate the role of substrate curvature on the microstructure and the residual stresses in the coating system The residual stresses generated in the thermal barrier coating (TBC) and the thermally grown oxide (TGO) have been evaluated non-destructively by Raman spectroscopy (RS) and photo-stimulated luminescence piezo-spectroscopy (PLPS), respectively In addition, residual stresses were measured in free-standing individual columns extracted from the TBCs for further understanding of the large Raman shift towards the tension side in the ceramic layer For the TGO, three areas with varied substrate curvature were mapped by PLPS These residual stresses are analysed as a function of the thermal exposure and the substrate curvature Discussion focuses on the implications on how to correctly evaluate the residual stresses in EBPVD-TBCs based on Raman shifts and subsequently the role of substrate curvature on the degradation of the microstructure and evolution of residual stresses in this type of TBCs

Effect of substrate curvature on the evolution of microstructure and residual stresses in EBPVD-TBC

Effect of material properties on residual stress distribution in thermal barrier coatings

In a thermal barrier coating (TBC) system with cylindrical geometry, the position of coating plays an important role in the distribution of residual stress. In this paper, the residual stress field in three different types of TBCs with cylindrical geometry has been analyzed. The main focus is on the effects of substrate curvature radius, deposition temperature and coating thickness on the residual stress distribution during a deposition process. The results show that the substrate curvature radius significantly affects the distributions of radial and hoop residual stresses, which are in good agreement with experimental measurements by photo-stimulated luminescence piezospectroscopy (Wang et al., Acta Mater., 2009, 57(1):182–195). The maximum radial residual stress locates closely to the coating/thermal grown oxide interface. However, the maximum hoop residual stress lies in the thermal grown oxide layer, which is much more than other three layers and presents a strong stress singularity along the thickness direction.

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Effects of substrate curvature radius, deposition temperature and coating thickness on the residual stress field of cylindrical thermal barrier coatings

J.P. Jiang

Papers

Effects of substrate curvature radius, deposition temperature and coating thickness on the residual stress field of cylindrical thermal barrier coatings