Failure of Electron Beam Physical Vapor Deposited Thermal Barrier Coatings System under Cyclic Thermo-Mechanical Loading with a Thermal Gradient

The failure mechanism of a thermal barrier coatings (TBCs) system is investigated using cyclic thermo-mechanical loading with a thermal gradient. Hollow circular cylindrical specimens are employed, consisting of a nickel-based single-crystal alloy DD6 coated with a NiCoCrAlYHf bond coat via arc-ion plating and a surface electron beam physical vapor deposited (EB-PVD) yttria-stabilized zirconia topcoat. The experimental setup allows for a surface temperature of 1130 degrees C and a substrate temperature of 1070 degrees C, while a tensile mechanical load of 200 MPa is employed to simulate the centrifugal stress in the middle of the high-pressure turbine blade. The comparison between TBCs with and without mechanical loading implies that the coupled thermo-mechanical load significantly promotes coating spallation since the superposition of mechanical strain enhances the local tensile stress at the peak region of the topcoat/thermally grown oxides (TGOs) interface. A subsequent interfacial morphology analysis demonstrates that the topcoat/TGO interface exhibited a degradation in the direction parallel to the mechanical loading axis. For all the specimens, TGO comprises a duplex structure, consisting of outer spinel and inner alpha-Al2O3.