Strength Degradation and Failure Mechanisms of Electron-Beam Physical-Vapor-Deposited Thermal Barrier Coatings

Failure mechanisms were determined for electron-beam physical-vapor-deposited thermal barrier coating (TBC) systems from the degradation of mechanical properties and microstructural changes in a furnace cycle test. Bond strength degradation for TBCs resulted from the initiation and growth of interfacial delamination defects between the yttria-stabilized zirconia topcoat and the thermally grown alumina (TGO). It is proposed that defects started from concave depressions in the bondcoat surface created by the grit-blast-cleaning process and that defect growth was driven by the reduction in compressive strain in the TGO as the alumina deformed into and displaced the bondcoat during the cooling cycles. Inclusion of yttrium in the substrate resulted in a doubling of the furnace cycle life of the TBCs because of enhanced fracture toughness of the TGO-bondcoat interface.