Abstract
Elastic–plastic finite element models are used to define the thermal/residual stress state responsible for the observed failure behavior of an electron beam physical vapor deposited yttria stabilized zirconia thermal barrier coating on a Pt–Al bond coat. The failures were observed to start at grain boundary ridges, some of which evolved into oxide filled cavities. Finite element models are made of the actual interface geometries through the use of metallographic sectioning and image processing. There is a one to one correspondence of calculated tension in the oxide layer and the observed localized damage. Purely elastic analysis failed to show some important tensile regions associated with the observed failure.
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