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Degradation evolution and failure mechanisms of air plasma-sprayed thermal barrier coatings during thermal cycling were investigated using microstructural and acoustic emission analysis. The microcrack evolution observed suggests that the life-time is governed by the kinetics of crack formation, growth and linking of individual cracks. The damage in the thermal barrier coatings mainly occurs during cooling due to thermal-expansion mismatch stresses at the metal – ceramic interface. The effect of the minimum cycling temperature on the lifetime was found to be much more pronounced than that of a variation in cooling rate. Experimental results were supported by finite element modeling of the stress distribution at the metal – ceramic interface during cooling at different rates.

Microstructural and acoustic damage analysis and finite element stress simulation of air plasma-sprayed thermal barrier coatings under thermal cycling