Failure of physical vapor deposition/ plasma-sprayed thermal barrier coatings during thermal cycling

ZrO sub(2)-7 wt.% Y sub(2)O sub(3) plasma-sprayed (PS) coatings were applied on high-temperature Ni-based alloys precoated by physical vapor deposition with a thin, dense, stabilized zirconia coating (PVD bond coat). The PS coatings were applied by atmospheric plasma spraying (APS) and inert gas pla...

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Bibliographic Details
Published in:Journal of thermal spray technology 2000-06, Vol.9 (2), p.191-197
Main Authors: TEIXEIRA, V, ANDRITSCHKY, M, GRUHN, H, MALLENER, W, BUCHKREMER, H. P, STÖVER, D
Format: Article
Language:English
Subjects:
Applied sciences
Ceramic coatings
Coatings
Exact sciences and technology
Failure mechanisms
Finite element method
Heat transfer
High temperature testing
Metals. Metallurgy
Nickel alloys
Nonmetallic coatings
Physical vapor deposition
Polystyrene resins
Production techniques
Stresses
Surface treatment
Thermal barrier coatings
Thermal cycling
Thermal gradients
Vapor deposition
Yttrium compounds
Zirconia
Zirconium dioxide
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Summary:ZrO sub(2)-7 wt.% Y sub(2)O sub(3) plasma-sprayed (PS) coatings were applied on high-temperature Ni-based alloys precoated by physical vapor deposition with a thin, dense, stabilized zirconia coating (PVD bond coat). The PS coatings were applied by atmospheric plasma spraying (APS) and inert gas plasma spraying (IPS) at 2 bar for different substrate temperatures. The thermal barrier coatings (TBCs) were tested by furnace isothermal cycling and flame thermal cycling at maximum temperatures between 1000 and 1150 degree C. The temperature gradients within the duplex PVD/PS thermal barrier coatings during the thermal cycling process were modeled using an unsteady heat transfer program. This modeling enables calculation of the transient thermal strains and stresses, which contributes to a better understanding of the failure mechanisms of the TBC during thermal cycling. The adherence and failure modes of these coating systems were experimentally studied during the high-temperature testing. The TBC failure mechanism during thermal cycling is discussed in light of coating transient stresses and substrate oxidation.
ISSN:1059-9630
1544-1016
DOI:10.1361/105996300770349917