Effect of segmented cracks on TGO growth and life of thick thermal barrier coating under isothermal oxidation conditions

This paper is devoted to a comparative study on the isothermal oxidation of thick thermal barrier coating (TTBC) with and without segmented cracks produced by atmospheric plasma spray (APS) process. Accordingly, the growth of thermally grown oxide (TGO) and its effect on the degradation of the coating were investigated. Thick top coat in both segmented crack and conventional thick TBC reduced the double layered TGO growth rate slightly. The segmented crack thick TBC demonstrated longer isothermal oxidation life in comparison with that of the conventional thick TBC at 1100 °C. The dominant failure mechanism was spallation due to lateral cracking within the TGO and/or within TBC near the TGO layer, called mixed failure. Stress, and consequently strain, induced on the TTBC due to progressive TGO growth, seems to be primarily responsible for the crack initiation and propagation leading to the coating failure. Increment of elastic energy stored within the top coat due to the increasing of TGO thickness, finally causes thick thermal barrier coating failure in high temperature isothermal oxidation.