Thermal Shock Experiments Research Articles

Structural characteristics and evolution in the crack propagation process of NiCrAlY/YSZ gradient coatings through thermal shock at 900 °C

In this study, four different thicknesses of NiCrAlY/8YSZ gradient coatings were fabricated using atmospheric plasma spraying (APS) technology. The failure behavior and lifetime of coatings were subsequently compared and analyzed through thermal shock experiments. The results revealed a pronounced correlation between the initiation and propagation of internal cracks within the gradient coatings and the thickness of the gradient region at a thermal shock temperature of 900°C. Both horizontal and vertical cracks were observed to propagate and interconnect, with horizontal crack propagation being the primary cause of coating failure. Notably, samples featuring a gradient region thickness of 150μm exhibited superior thermal shock resistance, suggesting promising prospects for enhanced coating durability.

Effect of thermal shock on energy density of biaxially oriented polypropylene films for pulsed power capacitors

In this paper, thermal shock experiments are performed on the biaxially oriented polypropylene (BOPP) films, and the changes in dielectric and energy storage properties before and after the experiments are explored. The experimental results show that the films have reduced comprehensive performance with the thermal shock time and frequency increasing. After the thermal shock, both the permittivity and the dielectric loss increase slightly. And, the direct current (DC) conductivity has risen by 73.6%–714.2%. The lowest DC breakdown strength of film is 604.4 kV mm−1, showing a 13.5% reduction compared to that of pristine film. In addition, energy storage performance has also deteriorated. The maximum discharge energy density decreased from 4.62 J cm−3 of pristine film to 3.26 J cm−3 of treated film. There is a decrease in charge and discharge efficiency under the same electric field. The metallization layer of the film receives less influence; the capacitance is reduced by only 0.37%. The causes and mechanisms of performance changes are analyzed and discussed. The disruption of molecular chains during thermal shock is the most important factor leading to the degradation of films. This paper provides a powerful perspective and reference for studying the performance degradation and failure of polymer dielectrics under extreme operating conditions.

A New Process for Efficient Non-Destructive Metal-Activated Composite Plating of Ni-P-Al2O3 on Titanium Base and Its Performance Research

A new high efficient and non-destructive mental activation process of electroless composite plating was proposed. The process utilized electromagnetic induction equipment to heat the titanium alloy substrate and used its energy to complete the activation process, which could successfully attach the nickel nanoparticles firmly to the surface of the titanium alloy; at the same time, the process pre-activated Al2O3 nanoparticles and added the activated nanoparticles to the plating solution. In the process of plating, the activated titanium substrate was used as the catalytic center of electroless nickel plating (ENP) for electroless composite plating. The new activation process avoided complicated traditional processes such as acid etching and zinc dipping. Such traditional processes require huge doses of chemicals, including various strong acids, so improper waste liquid treatment will cause harm to the environment. The important parameters of the process were optimized by orthogonal experiments. A scanning electron microscope (SEM), an X-ray photoelectron spectroscopy (XPS), an energy dispersive spectrometer (EDS), thermal shock experiments and friction and wear experiments were used to characterize and analyze the surface morphology, composition, binding force and friction coefficient of the coating, and analyze the coating quality by measuring the plating rate and the thickness of the coating. The results showed that the rate of electroless composite plating increased with the increase in Al2O3 nanoparticle concentration. When the concentration of Al2O3 nanoparticles reached 1.5 g/L, the ENP rate decreased with the increase in Al2O3 nanoparticle concentration. The adhesion of the sample was evaluated by the scratch test, which showed that the binding grade of the sample was 0, and the Vickers hardness was 688.5 HV. Results showed that the coating produced by this new process has excellent performance. Therefore, the process is an environmentally friendly and fast activation composite plating process.

Grain-based coupled thermo-mechanical modeling for stressed heterogeneous granite under thermal shock

Microscopic damage and macroscopic mechanical properties of granite under the coupling effect of thermal load and initial stress are crucial considerations for the safe construction of underground geo-energy engineering. However, visualizing real-time micro-crack processes in rocks under high-temperature and high-pressure conditions using the current experimental techniques remains challenging. In this study, a numerical method is developed to analyze the thermally induced damage in heterogeneous granite under the coupled influence of initial stress and thermal loading. A biaxial thermo-mechanical grain-based model considering real mineral distribution is established based on digital image processing technology, the grain-based modeling method, and heat conduction theory. The microscopic parameters are calibrated and the effectiveness of the model is verified based on thermal shock and uniaxial compression experiments. The thermal destruction mechanism of granite under initial stress from a microscopic perspective was unveiled for the first time. During the thermal shock process, the stress within the rock does not remain constant at the initial stress value. Instead, it changes continuously with the progression of heat conduction. The impact of the initial stress on the thermally induced cracks is relatively minor. Cooling causes more damage to the rock than heating during thermal shock. The intragranular cracks of quartz consistently outnumber other intragranular or intergranular cracks during thermal shock. The initial stress and thermal shock damage enhance and weaken the biaxial peak strength of granite, respectively. The weakening effect of thermal shock on the peak strength becomes more pronounced at a higher initial stress. These research findings and proposed research techniques contribute to the management and optimization of underground geo-energy engineering.

Enhanced broadband infrared radiation from rare earth orthochromites for High-Temperature radiative heat transfer

The development of broadband, high-performance infrared radiation materials is crucial for energy conservation and applications in aerospace and industrial sectors. Rare earth orthochromites, such as PrCrO3, exhibit good thermal stability and high infrared emissivity beyond the 6 μm wavelength range. However, their large bandgap limits their infrared emissivity before 6 μm, significantly impacting their potential applications. Herein, we have successfully enhanced the thermal emissivity of PrCrO3 by manipulating oxygen vacancies (OV) and accompanying impurity levels, leading to the synthesis of five rare earth orthochromites. Compared with pristine PrCrO3, co-doping of Ca, Co, and Mn introduced oxygen vacancies (OV) and impurity energy levels, effectively reducing the band gap and improving emissivity in the wavelengths below 6 μm. In particular, the infrared emissivity of (Pr0.3Y0.3Ca0.4)CrO3 in the wavelengths of 0.78–2.5 μm reaches 0.89, which is double than that of pristine PrCrO3. Furthermore, its thermal stability is excellent, as demonstrated by thermal shock experiments at 1500 ℃ for five cycles. More importantly, the developed orthochromites can be applied as a coating on substrates such as alumina ceramic sheets, exhibiting an average infrared emissivity of 0.95 and remarkable radiative heat transfer capability. This research contributes to the advancement of high-performance infrared radiation materials by vacancy engineering.

Near-zero thermal expansion ZrW2O8/SiO2f wave-transparent composites: Interfacial anti-debonding structures based on polymeric films

The thermal stability of fiber-optic gyroscopes (FOGs) limits their application in harsh environments. This work utilized the unique water-retention properties of hyaluronic acid and the low-temperature cold sintering process combined to fabricate near-zero thermal expansion ZrW2O8/SiO2f composites with thermal resistance. Based on this novel process, the interface debonding of the composites is effectively suppressed and the mechanical and thermal properties of the composites are significantly improved (flexural strength increased by 69.47 %). Moreover, the interface anti-debonding structure reduces the interfacial polarization and reflection loss of the composites, and enhances the wave-transparent properties in the 2–18 GHz frequency range, with a minimum reflection loss of −0.21 dB. Furthermore, the interface anti-debonding structure of the composite provides creep resistance with enhanced sintering densities (increased by 13.61 %). Simultaneously, the composites achieve a controllable coefficient of thermal expansion (CTE) by regulating the liquid phase content and reach near-zero CTE (−0.246 × 10−6 °C−1 [30–300 °C]). Finally, finite element analysis and thermal shock experiments show that the anti-debonding interfacial structure has excellent thermal resistance, and the densest ZrW2O8/SiO2f composites exhibit the best thermal resistance due to minimal thermal strain during thermal shock, which is expected to meet the requirements of FOGs applications.

Deuterium retention in cyclic transient heat loaded tungsten with increasing cycle numbers

Surface damage and microscopic defect evolution of tungsten (W) armor under transient heat loads are key factors for fuel retention in fusion reactors. In this work, experiments were conducted to investigate the effects of cyclic thermal shocks on deuterium (D) retention and surface blistering in W. Thermal shock experiments were conducted on recrystallized W using an electron beam with a power density of 0.15 GW m−2 across 100–1500 cycles, followed by D plasma exposure with high-fluence (∼1 × 1026 D m−2). The results demonstrate that samples subjected to 500 and 1500 cycles exhibit a significant presence of sub-grains within 90 μm. Notably, the inhibition of blistering induced by thermal shock leads to a substantial reduction in D retention (5.45 × 1019 D m−2) at lower cycle numbers (100 cycles) compared to the reference sample (2.35 × 1020 D m−2) which was only exposed to D plasma. When cycle numbers increase to 500 and 1500, D retention reaches 1.98 × 1020 D m−2 and 4.56 × 1020 D m−2, respectively. Based on the tritium migration analysis program, we propose that total D retention is a consequence of the competition between defects reduced by thermal shock-induced suppression of blistering and defects generated by plastic deformation induced by thermal stress. D retention initially decreases with the increase in cycle numbers, followed by a subsequent rise, with the inflection point slightly higher than 500 cycles. Additionally, due to the extensive scope of thermal stress, an escalated exposure period will result in substantial D captured by heat-induced defects, consequently intensifying the D retention. Whether there exists an upper limit to D retention induced by the increasing thermal shock cycles necessitates further experimental analysis. Nonetheless, it is evident that thermal shock significantly contributes to D retention within a profoundly deep bulk region under high cycles.

On the Thermal Shock Resistance and Failure Mechanism of the Pt-Modified Aluminide Bond Coating

The failure mechanism of the Pt-modified aluminide (Pt-Al) bond coating (β-(Ni, Pt)Al coating) in a simulated service environment has seldom been investigated. Based on a self-developed thermal barrier coating service environment simulator, a thermal shock experiment of single-phase Pt-Al bond coating on DD419 substrate at a temperature of 1170 °C was conducted combined with a real-time monitoring infrared thermal imager. The lifespan and failure mechanism of the coating are analyzed in detail. The results reveal that specimens of the Pt-Al bond coating, subjected to three repeated tests, exhibit failure after 650, 528, and 793 thermal shock cycles at 1170 °C, respectively. After failure, the contents of Pt and Al elements in the peeled region are lower than those in the unpeeled area, and a diffusion zone emerges in the bond coating. The failure mechanism of the Pt-Al bond coating during the thermal shock test can be attributed to three main aspects: (1) the diffusion and consumption of the Pt element reduced the oxidation resistance of the Pt-Al bond coating; (2) the diffusion and depletion of elemental Al causes a phase change in the coating, leading to the failure of the coating; (3) thermal stresses are generated in the Pt-Al bonded coating during the thermal shock test, which ultimately leads to wrinkling.

A Finite Element Study of Thermal Shock Load Effects on Dental Material before on the Two-body Wear Mechanisms

Abstract Background: The thermal changes environment is a parameter that affects the dental mechanical and esthetic behavior of materials. Dental materials placed in the human oral environment are inevitably exposed to thermal changes environments during chewing movement and hot or cold fluids. Aim: Therefore, this study aims to analyze the surface behavior of a dental material placed in the human mouth in thermal changes according to the finite element method. Materials and Methods: Cylindrical titanium alloy samples with a diameter of 12 mm were prepared for thermal shock load simulation. Withinthe scope of this study, the samples were divided into two equal groups. While the first group test samples were subjected to thermal shock experiments, the others were determined as the control group. The surface temperature distributions of the samples in the test procedures were analyzed and evaluations were made on the wear behavior of the materials. Results: The temperature distributions showed density on the material surface and it was analyzed that a temperature transfer took place toward the inside of the material. Conclusion: This result is evaluated as behavior that reduces the wear resistance since it directly affects the contact surface in the two-body (direct-contact) wear mechanism.

Abnormal variation of P-wave velocity of red sandstone after cyclical thermal shock in water

Hot dry rock (HDR) has great development potential because of its advantages of clean, environmental protection and renewable. The study of physical and mechanical properties of HDR is one of the important links in the process of geothermal energy development. Previous studies have mainly focused on the granite thermal reservoir but research on the sandstone thermal reservoir, especially the physical properties of sandstone after multiple thermal shocks, is scarce. Therefore, in this study, cyclic thermal shock experiments of sandstone at different temperatures are carried out, and the variation law of P-wave velocity of sandstone after heat treatment is revealed. It is found that the P-wave velocity of red sandstone decreases with the increase of temperature and cycle times, especially when the temperature is higher than 400 °C, the maximum change rate of wave velocity reaches 52.6%. It is particularly noteworthy that the P- wave velocity of sandstone increases abnormally at about 600 °C. And this article puts forward three hypotheses to explain the wave velocity anomaly. In addition, the nonlinear relationship model among P-wave velocity, temperature and number of cycles is established for the first time, and the correlation coefficient R2 is more than 0.9. This study serves as a reference for the development and utilization of the sandstone geothermal reservoir.

Multi-factor coupled failure mechanism of W–Cu functionally graded material under thermal shock service

The stability of W–Cu functionally graded material (FGM) as a heat sink connecting material is of significant importance for long-term service under high-temperature thermal cycling conditions. In this study, W–Cu FGM was successfully fabricated by powder metallurgy method. Various thermal shock experiments were performed on the samples at different temperatures and cycles, and a comprehensive investigation was conducted into its service failure mechanisms. The findings demonstrate that as the temperature increases to 1000 °C, the layer with low copper content gradually developed microcracks, and the microstructure changed from the original uniform distribution to a copper granular exudation, ultimately forming a network-like copper layer. The layer with high copper content undergoes a transition from slight undulations and roughness to the emergence of numerous cracks and pores, accompanied by the formation of a larger area of copper pool structures. After 1000 °C thermal shock for 200 cycles, the thermal conductivity decreases from 215.33 W m−1 K−1 to 168.24 W m−1 K−1, the bending strength decreased from 686.75 MPa to 115.77 MPa at room temperature, with reductions of 22.4 % and 81.2 %, respectively. At this point, the sample severely failed. The study highlights that the thermal shock failure mechanism of the gradient W–Cu samples is a novel multifactor coupled failure mechanism. It is influenced by the combined effects of crack initiation and propagation induced by thermal stress and the evolution of microstructural changes.

Preparation of transparent anodic aluminum oxide films and their structural characteristics under thermal shock

Anodic aluminum oxide (AAO) films have a wide range of research and applications in the field of nanoscience and technology. Transparent AAO films require the oxide layer to be peeled off from the aluminum substrate to which it is attached, involving a complex preparation process and immersion in a variety of caustic solutions, resulting in the prepared AAO films that are very prone to fragmentation and unfavorable for applications. Here, we have prepared transparent AAO films by double-sided anodization method with secondary anodization, which consists of a double-sided porous structure spaced with a barrier layer. These transparent AAO films can be bent into bow shape and exhibit good toughness under the action of external forces applied at both ends. Then, the transparent AAO films were subjected to thermal shock experiments, and the changes in the microstructure of the AAO films before and after the thermal shock were analyzed. The relationship between the microstructure of the AAO films and the good toughness they exhibit was also investigated.

Improving the high-temperature oxidation resistance of CrN coating by gradient deposition considering internal stress effects

In this study, two different CrN coatings were deposited on the surface of Zr-4 via a multi-arc ion-plating method using gradient and non-gradient deposition processes. The effects of two deposition processes on the high-temperature oxidation resistance and internal stress of the coatings were investigated. The microstructure and phase structure of the coatings were characterized by scanning electron microscopy, X-ray diffraction (XRD), and energy dispersive spectrometry. The high-temperature oxidation resistance of the specimens was investigated by performing thermal shock experiments and simulated loss-of-coolant accident high-temperature steam oxidation experiments. The residual stresses of both coatings during deposition were determined by XRD analysis. In addition, the thermal stresses of both coatings during the high-temperature oxidation tests were modeled and calculated. Under long-term high-temperature oxidation conditions, the gradient-deposited CrN coating exhibited improved high-temperature oxidation resistance performance than that exhibited by non-gradient-deposited CrN coating. In addition, the residual stresses of gradient-deposited CrN coating during deposition and thermal stresses during high-temperature oxidation were significantly lower than those of the non-gradient-deposited CrN coating. The results obtained herein confirm the promising potential of gradient-deposited CrN coating as an accident-tolerant fuel cladding material.

Effect of High-Temperature Thermal Shock on Solar Absorption Rate of Alumina Coating

With the development of the aerospace industry, the close exploration of the Sun has become a human demand. However, close-range exploration means that the detection satellite needs to accept the test of high temperatures above 1400 °C, so a thermal protective coating is a necessary part of the detection satellite to isolate heat and reflected light. Al2O3 coating has the characteristics of high emissivity and low absorptivity, and it is the best choice for thermal protection coating. However, the coating is subjected to thermal cycles, including heating and cooling, as the satellite rotates around the Sun, which could result in a change in the structure and properties of the coating. Therefore, thermal shock experiments were carried out, and the influence of microstructure on the absorption rate of the Al2O3 coating was investigated. In this study, an Al2O3 coating was prepared by atmospheric plasma spraying (APS). The coating was subjected to a thermal shock (TS) test at 1400 °C using a self-made flame shock device, and coating samples under different thermal shock degrees were obtained. A scanning electron microscope (SEM) was used to characterize the coating pores, and the effects of the coating pore size, aspect ratio (A/R) and cracks in the coating on the optical properties of the coating under different thermal shock degrees were analyzed. In order to clarify the influence of coating microstructure changes on the optical properties of the coating under different thermal shock degrees, not only relevant experiments were carried out, but also the solar reflectivity of Al2O3 coatings with different pore structures was analyzed by the finite element method using finite-difference time-domain (FDTD). The results show that increasing the porosity and aspect ratio of the pores can improve the partial solar absorption of the coating. It was also found that the transverse crack propagation improves the solar reflectance of the coating.

Effect of CMAS attack behaviour on stress distribution in double-ceramic-layer thermal barrier coatings

Stress distribution has a significant effect on crack nucleation and propagation in thermal barrier coatings (TBCs). The stress distribution of different types of double-layer plasma-sprayed coatings, such as YbYSZ/YSZ (YbYSZ: Yb2O3-Y2O3 co-stabilised ZrO2; YSZ: Y2O3 stabilised ZrO2) and YbYSZ/EMAP-YSZ (EMAP-YSZ: embedded micron-agglomerated particle-YSZ) coatings, was numerically studied using the finite element method (FEM) under the condition of thermal shock experiments coupled with calcium-magnesium-alumina-silicate (CMAS) attack. The maximum stress increased with the increasing thickness of CMAS deposition when CMAS was deposited on the coated surface. Among the three coatings of YSZ, YbYSZ/YSZ, and YbYSZ/EMAP-YSZ attacked by CMAS, the stress change of the YbYSZ/EMAP-YSZ coating was lower when CMAS was deposited on the surface of the ceramic layer and penetrated 200 μm below the original surface but was worse after penetration up to 250 μm. Furthermore, traditional YSZ in a CMAS environment was also compared to demonstrate the thermal shock life of double-ceramic layer coatings in a better manner. The relationship among CMAS attack, thermal shock, temperature distribution, stress distribution, and cracking initiation of TBC systems has been clarified to provide significant insight in understanding the failure mechanism and important guidance for optimising TBCs to enhance their service life.

Study on thermal shock resistance of Sc2O3 and Y2O3 co-stabilized ZrO2 thermal barrier coatings

In order to reveal the effect of Sc2O3 and Y2O3 co-doping system on the thermal shock resistance of ZrO2 thermal barrier coatings, Y2O3 stabilized ZrO2 thermal barrier coatings (YSZ TBCs) and Sc2O3–Y2O3 co-stabilized ZrO2 thermal barrier coatings (ScYSZ TBCs) were prepared by atmospheric plasma spraying technology. The surface and cross-section micromorphologies of YSZ ceramic coating and ScYSZ ceramic coatings were compared, and their phase composition before and after heat treatment at 1200 °C was analyzed. Whereupon, the thermal shock experiment of the two TBCs at 1100 °C was carried out. The results show that the micromorphologies of YSZ ceramic coating and ScYSZ ceramic coating were not much different, but the porosity of the latter was slightly higher. Before heat treatment, the phase composition of both YSZ ceramic coating and ScYSZ ceramic coating was a single T′ phase. After heat treatment, the phase composition of YSZ ceramic coating was a mixture of M phase, T phase, and C phase, while that of ScYSZ ceramic coating was still a single T′ phase, indicating ScYSZ ceramic coating had better T′ phase stability, which could be attributed to the co-doping system of Sc2O3 and Y2O3 facilitated the formation of defect clusters. In the thermal shock experiment, the thermal shock life of YSZ TBCs was 310 times, while that of ScYSZ TBCs was 370 times, indicating the latter had better thermal shock resistance. The difference in thermal shock resistance could be attributed to the different sintering resistance of ceramic coatings and the different growth rates of thermally grown oxide in the two TBCs. Furthermore, the thermal shock failure modes of YSZ TBCs and ScYSZ TBCs were different, the former was delamination, while the latter was delamination and shallow spallation.

Analysis of 3D crack patterns in a free plate caused by thermal shock using FEM-bifurcation

Damage to components made of brittle material due to thermal shock represents a high safety risk. Predicting the degree of damage is therefore very important to avoid catastrophic failure. An energy-based linear elastic fracture mechanics bifurcation analysis using a three-dimensional finite element model is presented here, which allows the determination of crack length and crack spacing for a defined thermal load in a free plate. It is assumed that a hierarchical crack pattern is formed due to cooling penetration. The constant growth of the ideal regular pattern of hexagons can change into a pattern with a different symmetry by slightly changing the cooling conditions. This bifurcation point is determined by the second derivative of the mechanical potential with respect to the geometry of the crack front. The very high computational effort for the second derivative is reduced by describing the three-dimensional crack front with a limited number of Fourier coefficients. A one-dimensional transient temperature field at a sufficient distance from the plate edge is assumed. For alumina, the crack length and crack spacing curves are computed for different quenching temperatures and heat transfer coefficients. The corresponding final crack lengths are also calculated as a measure of damage. Comparison with a two-dimensional model confirms the expected 1/2 difference in crack spacing. Data from thermal shock experiments are also presented. However, due to the cracks caused by the strong cooling at the edge, these correspond to the results of the two-dimensional model.

Hot corrosion and thermal shock performance of nanoparticulate YSZ coatings deposited via suspension plasma spraying (SPS)

In this research, the preparation, and some thermal behaviors of nanoparticulate yttria stabilized zirconia (YSZ) coatings were assessed. Aqueous suspensions containing YSZ nanoparticles were produced and then used to deposit thermal barrier coatings through the suspension plasma spraying (SPS) method. Cyclic hot corrosion and thermal shock experiments were performed on the coatings in a Na2SO4–Na2VO3 molten salt at 880 °C and under rapid cycles at 1100 °C, respectively. The coating obtained from spraying of the optimal suspension, which includes YSZ nanoparticles dispersed with α-Terpineol as a surfactant, promisingly has a columnar-shaped structure. The lifetimes of this columnar SPS-YSZ coating during the hot corrosion and thermal shock experiments were measured to be 380 h and 120 cycles, respectively, whereas they were 240 h and 100 cycles for a laminar coating obtained from spraying of nonoptimized YSZ. It is concluded that by optimizing the water-based suspension of YSZ nanoparticles, novel thermal barrier coatings with an optimal microstructure can be achieved, which improves the properties of the coating and increases its lifetime.

Research on the technology of flame spraying aluminum coating for composite material

Aluminum coating was prepared on composite material surface by using oxygen-acetylene flame spraying technology. The H01-103H sealants were used to seal the thermal sprayed aluminum coatings. The characteristics of the aluminum coatings with and without H01-103H sealant, including surface morphologies, phase composition, and bonding strength, were investigated by means of SEM, EDS, and mechanical testing machine. Thermal shock experiment and low temperature cooling test were also used to examine the thermal shock resistance and frost resistance of the Al coatings. Electrical conductivity and electromagnetic shielding properties were then tested according to four-probe measurement principle and GJB 5239-2004, respectively. The results showed that the bond strength was 7.36 MPa and the surface porosity was about 5.21% for Al coating without H01-103H sealant, in addition, the H01-103H sealants could fill into the pores, reducing the porosity and increasing the bond strength of the coating. Furthermore, the main component of the coating was Al, the oxygen content was only 1.43%. Flame sprayed aluminum coating, with surface electrical resistance 0.89 mΩ and 5–18 GHz electromagnetic shielding effectiveness above 35 dB, was an ideal candidate for electromagnetic shielding utilization. The Al coating remained intact, compact, no cracks, peeling, layering under 50–200°C and −30°C, which showed good thermal shock resistance and frost resistance.

CMAS corrosion resistance, thermal shock resistance and numerical simulation of novel surface micromesh thermal barrier coatings

Thermal barrier coatings (TBCs) are widely used as insulating layers to protect the underlying metallic structure of gas turbine blades. However, the thermal cycling performance of TBCs is affected by their complex working environments, which may shorten their service life. Previous studies have shown that preparing a mesh structure in the bonding layer can relieve thermal stress and improve the bonding strength, thereby prolonging the service life of TBCs. In this paper, a micromesh structure was prepared on the surface of the bonding layer via wet etching. The microstructure and failure mechanism of the micromesh TBCs after CMAS (CaO-MgO-Al2O3-SiO2) thermal erosion were investigated. Numerical simulation was combined with thermal shock experiments to study the stress distribution of the micromesh-structured TBCs. The results showed that the circular convex structure can effectively improve the CMAS corrosion resistance and thermal shock resistance of TBCs.