Effect of bond coat topography on the fracture mechanics and lifetime of air-plasma sprayed thermal barrier coatings

Abstract

A modified four-point bending test was conducted on air-plasma sprayed (APS) thermal barrier coatings (TBC) to investigate the impact of bond coat (BC) topography tortuosity on the TBC fracture mechanics. The degree of BC tortuosity was quantified by the novel total thresholded summit area surface descriptor (Ssth) and was found to influence the crack path configuration, critical energy release rate (Gc) and crack propagation velocity (νprop). Specimens with higher BC interface tortuosity and more compliant TBC microstructures displayed a reduced strain energy release rates (Gc ≤ 79.90 J. m−2) and crack propagation velocities (vprop ≤ 0.90 mm. s−1). Delamination was primarily governed by the degree of inter-splat cohesion and intra-splat segmentation, although the topography-induced inter-splat tortuosity still had a relevant impact on fracture mechanics. The correlation observed between these results and the lifetime of analogous thermally cycled specimens tested herein suggests that the BC interface can affect the effectiveness of the microstructural stress relaxation mechanisms and by extension the TBC durability.