High-temperature degradation of plasma sprayed thermal barrier coating systems

Thermal barrier coating systems (TBCs) are used in gas turbines to prevent high-temperature degradation of metallic materials in the combustor and turbine. One of the main concerns regarding TBCs is poor reliability, and accurate life prediction models are necessary in order to fully utilise the beneficial effects of TBCs. This research project aims at developing deeper understanding of the degradation and failure mechanisms acting on TBCs during high temperature exposure, and to use this knowledge to improve life assessments of TBCs. The present work includes a study on the influence of coating interface morphology on the fatigue life of TBCs and a study on the influence of some different heat treatments on the adhesive properties of TBCs. The influence of coating interface morphology on fatigue life has been studied both experimentally and by modelling. Large interface roughness has been found experimentally to increase fatigue life of TBCs. The modelling work do, to some extent, capture this behaviour. It is evident, from the study, that interface morphology has a large impact on fatigue life of TBCs. Three thermal testing methods, that degrade TBCs, have been investigated: isothermal oxidation, furnace cycling and burner rig test. The degraded TBCs have been evaluated by adhesion tests and microscopy. The adhesion of TBCs has been found to depend on heat treatment type and length. Cyclic heat treatments, (furnace cycling and burner rig test), lower the adhesion of TBCs while isothermal oxidation increases adhesion. The fracture surfaces from the adhesion tests reveal that failure strongly depends on the pre-existing defects in the TBC.