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The TC/BC interface morphology in APS TBC is one of the important factors leading to crack propagation and coating failure. Long cracks are found near the bulge on the TC/BC interface. In this study, the TBC model with the bulge on the interface is developed to explore the influence of the bulge on the coating failure. Dynamic TGO growth and crack propagation are considered in the model. The effects of the bulge on the stress state and crack propagation in the ceramic layer are examined. Moreover, the effects of the distribution and number of bulges are also investigated. The results show that the bulge on the interface results in the redistribution of local stress. The early cracking of the ceramic layer occurs near the top of the bulge. One bulge near the peak or valley of the interface leads to a coating life reduction of about 75% compared with that without a bulge. The increase in the number of bulges further decreases the coating life, which is independent of the bulge location. The results in this work indicate that a smooth TC/BC interface obtained by some possible surface treatments may be an optional scenario for improving coating life.

Understanding the Failure Mechanism of Thermal Barrier Coatings Considering the Local Bulge at the Interface between YSZ Ceramic and Bond Layer