Effects of Interface Roughness on Residual Stresses in Thermal Barrier Coatings

• Published in: Journal of the American Ceramic Society Vol. 82; no. 4; pp. 1073 - 1075
• Main Authors: Hsueh, Chun-Hway, Haynes, James A., Lance, Michael J., Becher, Paul F., Ferber, Mattison K., Fuller, Edwin R., Langer, Stephen A., Carter, W. Craig, Cannon, W. Roger
• Format: Journal Article
• Language: English
• Published: Westerville, Ohio American Ceramics Society 01.04.1999; Blackwell; Wiley Subscription Services, Inc
• Subjects: Applied sciences; Building materials. Ceramics. Glasses; Ceramic industries; Ceramics; Chemical industry and chemicals; Exact sciences and technology; Interface roughness; Miscellaneous; Residual stress; Technical ceramics; Thermal barrier coatings; Coating material; Roughness; Mechanical properties; Stabilized zirconia; Thermal barrier; Modeling; Oxide ceramics; Interface properties; Yttrium Oxides; Numerical simulation; Microstructure; Plasma spraying; Residual stress
• ISSN: 0002-7820; 1551-2916
• DOI: 10.1111/j.1151-2916.1999.tb01878.x

Using a newly developed object‐oriented finite‐element analysis method, both an actual microstructure and model microstructures of a plasma‐sprayed thermal barrier coating system were numerically simulated to analyze the full‐field residual stresses of this coating system. Residual stresses in the actual microstructure were influenced by both the irregular top‐coat/bond‐coat interface and cracks in the top coat. By treating the microcracked top coat as a more‐compliant solid microstructure, the effects of the irregular interface on residual stresses were examined. These results then could be compared to results that have been obtained by analyzing a model microstructure with a sinusoidal interface, which has been considered by some earlier investigators.