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

  • Interface Science in Thermal Barrier Coatings
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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.

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Acknowledgements

The authors are grateful to the following colleagues in the Institute for Energy Research of the Forschungszentrum Jülich for assistance in the materials procurement and experimental work: R. Vassen, K·H. Rauwald, H. Cosler, E. Wessel, M. Subanovic, and J. Toscano. Part of the present work was funded by the German Research Foundation (Grant No. NA-615-1) and German federal ministry for economy and technology (Grant No. 0326888D).

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Authors and Affiliations

  1. Forschungszentrum Jülich GmbH, IEF-2, 52425, Juelich, Germany

    Dmitry Naumenko, Vladimir Shemet, Lorenz Singheiser & Willem Josef Quadakkers

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  1. Dmitry Naumenko
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  2. Vladimir Shemet
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  3. Lorenz Singheiser
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  4. Willem Josef Quadakkers
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Correspondence to Dmitry Naumenko.

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Naumenko, D., Shemet, V., Singheiser, L. et al. Failure mechanisms of thermal barrier coatings on MCrAlY-type bondcoats associated with the formation of the thermally grown oxide. J Mater Sci 44, 1687–1703 (2009). https://doi.org/10.1007/s10853-009-3284-3

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