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The life span for a coating attached to its substrate is basic support for their desired protective function. Therefore, it is necessary to find out the causes responsible for the failure of coatings during service. This paper developed a finite element model to investigate the cracking behavior of plasma-sprayed ceramic coatings induced by the mismatch strain of thermal expansion between coating and substrate. Crack propagation affected by coating thicknesses was realized by the virtual crack closure technique (VCCT). The residual stresses (σ22 and σ12) and the strain energy release rate (SERR) induced at the tip of pre-crack in ceramic coatings are calculated. Results show that the σ22 and σ12 at the tip of the pre-crack increases continuously with the thickening ceramic coatings. The SERRs at the tip of the pre-crack in top-coat (TC) were increased with the thickness of ceramic coatings, resulting in the propagation of cracks. The crack length increases with the thickening of ceramic coatings. The crack propagation and coalescence lead to coating spallation, which is one of the main failure modes for plasma sprayed ceramic coatings during service. Given that, strain tolerant design was developed by inserting vertical pores in coatings. It was found that the SERRs were decreased with the increase in the number of vertical pores, as well as their depth. Moreover, the coatings with vertical pores appear to be crack-resistant, in particular for the thicker coatings. This suggests that the strain tolerant design is helpful to extend the life span of thick coatings, which makes a fundamental contribution to the design and preparation of advanced protective coatings in future applications.

Strain-Induced Cracking Behavior of Coating/Substrate Systems and Strain Tolerant Design for Thick Coatings