Experimental study on the interfacial delamination in a thermal barrier coating system at elevated temperatures

The failure mode and adhesion of thermal barrier coating (TBC) 8YSZ (ZrO2+8% (w/w) Y2O3) deposited on NiCoCrAlTaY bond coat by atmospheric plasma spraying were investigated. A grooved modified three-point bending specimen that can generate a single interface crack to facilitate the control of crack growth was adopted for testing, which was conducted at the ambient temperature of 100 °C. The morphology and composition of fractured surfaces were examined by means of a scanning electron microscopy (SEM) and an energy disperse spectroscopy (EDS). Images and spectrum show that cracks are initiated and propagated exclusively within YSZ layer adjacent to top/bond coat interface. The load-displacement curves obtained exhibit similar shapes that indicate two distinct stages in crack initiation and stable crack growth. Finite element analyses were performed to extract the adhesion strength of the TBCs. The delamination toughness of the plasma-sprayed 8YSZ coatings at 100 °C, in terms of critical strain energy release rate Gc, can be reliably obtained from an analytical solution.