Abstract
Cracking behavior has been considered for the top coating in the thermal barrier coating system. The effect of the dimension and position of non-bonded lamellar interfaces on the stress distribution is investigated by the simulation method. Plasma-sprayed yttria-stabilized zirconia coatings are deposited at different spraying distances. The crack propagation behavior is studied by statistical analysis after the coatings have experienced different thermal cycles. The simulation results reveal that the normal stresses at the tips of non-bonded lamellar interfaces increase with the increment of the length of interfaces and with the decrease of the distance between them. The stress level almost stays the same with the changing of lamellar thickness. Experimental results indicate the correctness of the simulation. It is found that the length of non-bonded lamellar interfaces in the as-deposited coatings shows an increasing tendency with the spraying distance. The total crack length of coatings increases with the number of thermal cycles and the spraying distance after thermal cycling tests.
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