Abstract
Yttria-stabilized zirconia (YSZ) coatings containing equiaxed grains and columnar grains were prepared by plasma spraying. Electron backscatter diffraction (EBSD) technology was firstly conducted to investigate effects of the grain shape on residual strain/stresses in as-sprayed YSZ coatings. It was found that equiaxed grains have larger strain capabilities than columnar grains and YSZ coatings with more equiaxed grains exhibited greater residual stresses than those with more columnar grains. It might be attributed to the higher temperature gradients existing in equiaxed grains caused by a higher cooling rate. Therefore, YSZ thermal barrier coatings with more columnar grains have a longer lifetime, which might be attributed to lower residual stresses in the columnar grains.
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