Abstract
A crack number density (CND) theory model is developed for air-plasma-sprayed thermal barrier coating (TBC), which describes the evolution of crack number and size distribution as function of exposure time. The model is compared in good agreement with experimental measurements from quasi-isothermal-cyclic oxidation tests. Both the CND model and experimental observations indicate that thermally-grown oxides (TGO) are responsible for crack nucleation and growth. The model can be used to define TBC failure (spallation) by coalescence of microcracks into a maximum allowable crack size with a given probability.
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