Near-Interface Crack Initiation in Thermal Barrier Coatings

Abstract

ABSTRACTThe delamination behavior of thermal barrier coatings (TBC) in transition ducts of inservice used combusters has been characterized using a protruded four-point bending testing technique recently developed by the authors. A reinforced protruded TBC specimen allowed the formation of TBC cracks adjacent to the TBC/alumina interface in a similar mode to inservice TBC failure. Finite element stress analysis showed that a peak transverse stress appeared in a protruded TBC part away from the interface and a large principal tensile stress operated on planes inclined to the interface. It was found that the onset of near-interface TBC cracks in the protruded TBC specimen did not occur under the high transverse and principal tensile stresses. The critical local tensile stress for the onset of TBC cracks near the interface, estimated to be 127 MPa, was lower than that of the near-center TBC. The near-interface TBC cracking behavior in the protruded TBC tests is discussed in light of the residual stress distribution and stressed volume effect.