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The influence of roughness profile shape, roughness depth, bond coat creep strength and pre-oxidation on the thermal cycling damage evolution and lifetime of a plasma-sprayed ZrO 2  thermal barrier coating system was investigated. A simplified model system was used where FeCrAlY substrates simulated the bond coat. Substrate creep was varied by using the oxide dispersoid strengthened alloy MA956 and the conventional material Fecralloy. Stochastic 3- and periodic 2-dimensional roughness profiles were produced by sand blasting and high speed turning. Damage evolution is significantly influenced by substrate creep with a trend to higher lifetimes for the fast creeping substrate. Pre-oxidation has no influence. Lifetimes of the periodically profiled samples are up to 100 times lower than these of stochastically profiled samples. In the case of periodically profiled samples, the highest lifetime was reached for the highest roughness depth combined with local undercuttings in the roughness profile. For stochastically profiled samples the influence of roughness depth could not be determined due to the wide lifetime scatter.

Thermal cycling damage evolution of a thermal barrier coating and the influence of substrate creep, interface roughness and pre-oxidation