Journal
JOURNAL OF THE EUROPEAN CERAMIC SOCIETY
Volume 40, Issue 15, Pages 5719-5730Publisher
ELSEVIER SCI LTD
DOI: 10.1016/j.jeurceramsoc.2020.05.082
Keywords
Bond coat interface topography; TBC lifetime; Total thresholded summit area; Microstructure; Elastic modulus
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Funding
- Rolls-Royce plc.
- Aerospace Technology Institute through Manufacturing Portfolio Project 2 [113081]
- EPSRC [EP/P025021/1, EP/S019367/1] Funding Source: UKRI
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The effect of bond coat/thermal barrier coating (BC/TBC) interface topography on the lifetime of air-plasma sprayed (APS) TBCs was comprehensively investigated in the present work. A quantitative description of the interface topography was achieved by utilising multiple surface texture parameters obtained from confocal microscopy, including a newly formulated parameter, denominated as total thresholded summit area, S-sth. Thermal cycling fatigue (TCF) testing showed a clear correlation between the TBC lifetime and the interface topography, especially for the novel S-sth parameter. The topographical and microstructural analysis revealed that deposition of a TBC over tortuous BC topographies leads to a highly curved TBC splat morphology, which in turn affected the crack path configuration. Mechanical testing of as-deposited and heat-treated specimens evidenced that the aforementioned microstructural changes promoted a reduced local and global elastic moduli, effectively linking the more compliant TBC microstructures with more beneficial fracture mechanics behaviours and higher TCF lifetimes.
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