Modeling the Build-Up of Internal Stresses in Multilayer Thick Thermal Barrier Coatings

Of the many factors affecting the durability and failure mechanisms of thermal spray coatings, in-service and residual stresses play an especially important role as the thickness of the coating increases. In this study, a numerical model for calculating the evolution of stresses within a multilayer coating during deposition is introduced. Model calculations are then validated by comparison with temperature and curvature measurements made during coating deposition.