A multi-scale constitutive model for the sintering of an air-plasma-sprayed thermal barrier coating, and its response, under hot isostatic pressing

A micromechanical model is developed for the sintering of an air-plasma-sprayed, thermal barrier coating, and is used to make predictions of microstructure evolution under free sintering and under hot isostatic pressing. It is assumed that the splats of the coating are separated by penny-shaped cracks; the faces of these cracks progressively sinter together at contacting asperities, initially by the mechanism of plastic yield and subsequently by interfacial diffusion. Diffusion is driven by the reduction in interfacial energy at the developing contacts of the cracks and also by the local contact stress at asperities. The contact stress arises from the remote applied stress and from mechanical wedging of the rough crack surfaces, Sintering of the cracks leads to an elevation in both the macroscopic Young's modulus and thermal conductivity of the coating, and thereby leads to a degradation in thermal performance and durability. An assessment is made of the relative roles of surface energy, applied stress and crack face roughness upon he sintering response and upon the evolution of the pertinent mechanical and physical properties. The evolution in microstructure is predicted for free sintering and for hot isostatic pressing in order to provide guidance for experimental validation of the micromechanical model. (C) 2009 Elsevier Ltd. All rights reserved.