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Functionally graded layers in thermal barrier coatings reduce the stress gradient between the overlaid ceramic coatings and the underlying metallic component. Introduced to alleviate early onset of spallation of the coating due to thermal expansion mismatch, this facilitates improvement in the life of the component. Conventional thermal barrier coatings typically comprise of duplex layers of plasma sprayed 8% yttria stabilized zirconia (ceramic) coatings on bond coated (NiCrAlY) components/substrates (Inconel 718 for example). This work highlights the superiority of plasma sprayed coatings synthesized from blends of the intermetallic bond coat and ceramic plasma spray powders on Inconel 718 substrates in three-layer configuration over the duplex layered configuration. Assessed through (a) thermal shock cyclic tests (at 1200oC and 1400oC) in laboratory scale basic burner rig test facility and (b) oxidation stability test in high temperature furnace (at 800oC and 1000oC) the functionally graded coatings of certain configurations exhibited more than double the life of the conventional 8% yttria stabilized zirconia duplex (double layer) coatings. Micro- and crystal structure analysis support the findings and results are detailed and discussed.

Thermal Shock and Oxidation Stability Tests to Grade Plasma Sprayed Functionally Gradient Thermal Barrier Coatings