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Influence of Topcoat-Bondcoat Interface Roughness on Stresses and Lifetime in Thermal Barrier Coatings

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Abstract

Failure in Atmospheric Plasma-Sprayed (APS) thermal barrier coatings (TBCs) is associated with the thermo-mechanical stresses developing due to the thermally grown oxide (TGO) layer growth and thermal expansion mismatch during thermal cycling. The interface roughness has been shown to play a major role in the development of these induced stresses and lifetime of TBCs. Modeling has been shown as an effective tool to understand the effect of interface roughness on induced stresses. In the previous work done by our research group, it was observed that APS bondcoats performed better than the bondcoats sprayed with High Velocity Oxy-Fuel process which is contrary to the present literature data. The objective of this work was to understand this observed difference in lifetime with the help of finite element modeling by using real surface topographies. Different TGO layer thicknesses were evaluated. The modeling results were also compared with existing theories established on simplified sinusoidal profiles published in earlier works. It was shown that modeling can be used as an effective tool to understand the stress behavior in TBCs with different roughness profiles.

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Acknowledgements

The authors would like to thank Kjell Niklasson at University West for the fruitful discussions and Stefan Rosén at Toponova AB for performing the white light interferometry and stripe projection measurements. Special thanks to Tobias Hansson, Chamara Kumara, and Sri Surya Pulim at University West for their help with simulation work.

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Authors and Affiliations

  1. University West, 46186, Trollhättan, Sweden

    M. Gupta, K. Skogsberg & P. Nylén

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  1. M. Gupta
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  3. P. Nylén
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Correspondence to M. Gupta.

Additional information

This article is an invited paper selected from presentations at the 2013 International Thermal Spray Conference, held May 13-15, 2013, in Busan, South Korea, and has been expanded from the original presentation.

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Gupta, M., Skogsberg, K. & Nylén, P. Influence of Topcoat-Bondcoat Interface Roughness on Stresses and Lifetime in Thermal Barrier Coatings. J Therm Spray Tech 23, 170–181 (2014). https://doi.org/10.1007/s11666-013-0022-9

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  • DOI: https://doi.org/10.1007/s11666-013-0022-9

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