Factors governing segmentation crack characteristics in air plasma sprayed ceramics

Air Plasma Spray (APS) is an industrially popular coating technique implemented in vast domains of applications. Among the inherent defects in an APS coating, segmentation cracks have been recognized to enhance the strain tolerance and durability of thermal barrier coatings. However, segmented coatings also exhibit higher thermal conductivity and are susceptible external debris infiltration. Hence, to optimize the coating properties, it is necessary to have processing control over the incorporation of such segmentation cracks. In this study, segmentation characteristics (thickness to cracking and crack spacing) of multiple Yttria Stabilized Zirconia (YSZ) and Gadolinium Zirconate (GZO) coatings were analyzed. The correlations between the processing parameters and the mechanical properties of the coatings were identified, and the cumulative effect of such variations on the segmentation characteristics were observed. In addition, the experimental observations were reconciled with fracture theories in thin films to provide a comprehensive phenomenological interpretation of segmentation in APS coatings.

Automated summary

Segmentation cracks in Air Plasma Spray coating can enhance strain tolerance and durability, but also increase thermal conductivity and susceptibility to external debris infiltration. By analyzing segmentation characteristics of different coatings, correlations between processing parameters and mechanical properties were identified, along with the cumulative effects of such variations on segmentation characteristics. Experimental observations were reconciled with fracture theories in thin films to provide a comprehensive phenomenological interpretation of segmentation in APS coatings.