Interface Science in Thermal Barrier Coatings

Journal of Materials Science

, Volume 44, Issue 7, pp 1687-1703

First online:

Failure mechanisms of thermal barrier coatings on MCrAlY-type bondcoats associated with the formation of the thermally grown oxide

  • Dmitry NaumenkoAffiliated withForschungszentrum Jülich GmbH Email author 
  • , Vladimir ShemetAffiliated withForschungszentrum Jülich GmbH
  • , Lorenz SingheiserAffiliated withForschungszentrum Jülich GmbH
  • , Willem Josef QuadakkersAffiliated withForschungszentrum Jülich GmbH

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Abstract

The effect of the thermally grown oxide (TGO) formation on the lifetime of the thermal barrier coatings (TBC) with MCrAlY-bondcoats (BC) is reviewed. A number of factors affecting the TGO-formation and TBC-failure are discussed including the coating microstructure, geometrical (coating roughness and thickness) and processing parameters. Under given testing conditions for a specific EB-PVD-TBC-system forming a flat, uniform alumina TGO a critical TGO-thickness for TBC-failure can be defined. This TGO-morphology is, however, not necessarily optimum for obtaining long TBC-lifetime, which can be extended by formation of TGO’s with an uneven TGO/BC interface. In contrast, APS-TBC-systems are prone to formation of intrinsically inhomogeneous TGO-morphologies. This is attributed to non-uniform depletion of Y and Al underneath rough MCrAlY-surfaces as well as due to the commonly observed repeated-cracking/re-growth of the TGO during temperature cycling. The latter phenomenon depends on the exposure temperature and the mechanical properties of the APS-TBC. In both types of TBC-systems the TGO-formation and TBC-lifetime appear to be very sensitive to the manufacturing parameters, such as vacuum quality during bondcoat spraying and temperature regime of the bondcoat vacuum heat-treatment.