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Residual stresses play an essential role in determining the failure mechanisms and life of an electron beam-physical vapour deposition thermal barrier coating (EB-PVD TBC) system. In this paper, a new transitional roughness model was proposed and applied to describe the interfacial roughness profile during thermal cycles. Finite element models were implemented to calculate residual stresses at specific positions close to the interface of TBCs using temperature process-dependent model parameters. Combining stresses evaluated at valleys of the topcoat (TC) and excessive sharp tip roughness profiles, positions where the maximum out-of-plane residual stresses occur were identified and used to explain possible cracking routes of EB-PVD TBCs as interfacial roughness evolves during thermal cycling.

The Effect of Interfacial Roughness on Residual Stresses in Electron Beam-Physical Vapor Deposition of Thermal Barrier Coatings