Life Prediction of Atmospheric Plasma-Sprayed Thermal Barrier Coatings Using Temperature-Dependent Model Parameters

The failure analysis and life prediction of atmospheric plasma-sprayed thermal barrier coatings (APS-TBCs) were carried out for a thermal cyclic process. A residual stress model for the top coat of APS-TBC was proposed and then applied to life prediction. This residual stress model shows an inversio...

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Bibliographic Details
Published in:Journal of thermal spray technology 2017-06, Vol.26 (5), p.902-912
Main Authors: Zhang, B., Chen, Kuiying, Baddour, N., Patnaik, P. C.
Format: Article
Language:English
Subjects:
Analytical Chemistry
Characterization and Evaluation of Materials
Chemistry and Materials Science
Corrosion and Coatings
Machines
Manufacturing
Materials Science
Peer Reviewed
Processes
Surfaces and Interfaces
Thin Films
Tribology
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Summary:The failure analysis and life prediction of atmospheric plasma-sprayed thermal barrier coatings (APS-TBCs) were carried out for a thermal cyclic process. A residual stress model for the top coat of APS-TBC was proposed and then applied to life prediction. This residual stress model shows an inversion characteristic versus thickness of thermally grown oxide. The capability of the life model was demonstrated using temperature-dependent model parameters. Using existing life data, a comparison of fitting approaches of life model parameters was performed. A larger discrepancy was found for the life predicted using linearized fitting parameters versus temperature compared to those using non-linear fitting parameters. A method for integrating the residual stress was proposed by using the critical time of stress inversion. The role of the residual stresses distributed at each individual coating layer was explored and their interplay on the coating’s delamination was analyzed.
ISSN:1059-9630
1544-1016
DOI:10.1007/s11666-017-0558-1