Degradation of thermal barrier coatings due to thermal cycling up to 1150°C

The degradation of thermal barrier coatings (TBCs) due to thermal cycling up to 1150degreesC has been studied. During thermal cycling, the bond coat in the TBCs was oxidised to form an alumina and a mixed oxide layer between the top coat of yttria stabilised zirconia (YSZ) and the bond coat of MCrAlY alloy. The mixed oxide layer mainly consists of alpha-Cr2O3 and (Ni,Co)(Cr,Al)(2)O-4 spinel phases, which are formed above the alpha-alumina layer. Interestingly, the alumina layer gradually disappeared during the oxidation while the content of chromium in the mixed oxide increased with increasing oxidation time. As the oxidation accelerated after the disappearance of the alumina layer, cracks initiated and propagated in the mixed oxide layer near the YSZ. Eventually, the crack propagation induced the spallation of some YSZ top coatings after the 2000 h oxidation. (C) 2002 Kluwer Academic Publishers.