Introduction

Thermal barrier coating (TBC), which is widely used in high temperature turbine blades, is made
up of ceramic top coat (TC), thermally grown oxide (TGO) and metal bond coat (BC) that
connects the TC layer with the super alloy substrate. Due to this structure of TBC system, the
various stress distribution appears around different material interfaces when TBC system
experiences variation of temperature.
Premature spallation failure of TBC is mainly caused due various mechanism such as residual
stresses, metal oxidations and geometrical factors [1]. Residual stress arises due to thermalexpansion coefficient and elastic property misfit when TBC is cooled down during fabrication or
operation temperature to reduced temperature [2, 3]. Due to the spraying process during
preparation uneven surface of TGO layer is prepared causing it to not an ideal plane , and
because of BC oxidation at high temperature this layer is thickened. TGO growth has great
influence on the TBC failure, primarily in growth stress and thermal mismatch stresses
associated with its growth, and these stresses far exceed the interfacial strength and lead to the
interface separation [4]. The geometrical factors plays an important role in interfacial crack
nucleation, due to interfacial morphologies and micro-structures, result in out-of-plane stress
normal to the metal/ceramic interface. Similarly the roughness of interface will be strengthened
due to the non-uniform growth of TGO during operation at elevated temperature, which makes
the evolution of residual stress in TBC system more complicated. The residual stress is normal to
TCTGO interface and TGO cause interfacial crack initiation and separation, and the TGO
thickness affects the distribution of residual stress [5]. The interface morphology is also an
important factor that influences the residual stress value and distribution. The residual stress
increases linearly with the interface amplitude and becomes zero in the vertical direction for
ideal plane interface which is impossible in practice. The evolution of TGO geometry under
thermal-mechanical cycles results in the instability of TBC system [4]. Evans [6] mentioned that
the high compressive stress within the coating and thermal mismatch stress within TBC system
are the fundamental causes of interfacial crack extension and failure of coatings. However, the
stress that makes the coatings fail is mainly caused by the rough TCBC interface morphology
.Thus, many researchers turn their attention to the stress state in the TCBC interface to find
explanations for TBC failure.

Theory

Temperature-dependent stress Ni(T):

In equation (1) above, describes the interfacial stresses between the and the bond coat
(). Where th (T) represents the mismatch strain between TGO and Ni-base
alloy due to their difference of thermal expansion coefficients. Ni base is the
Poissons ratio, A and represent the amplitude and wavelength of the
undulated interface respectively as described schematically in figure above.
While h is the thickness of TGO. In this study, we focus the location of y=
/4,where =48 m.
Temperature-dependence k(T):

and Ni base represents the Poisson ratios of and

Young moduli of and Ni base , respectively.

Ni base

. and Ni base are the

Temperature-dependent th (T) (T0= 280 K, T1= 1200 K):

th describes the thermal strain due to a difference of thermal expansion coefficient between the
and Ni base . Where Ni base and represent thermal expansion coefficients of and
Ni base. For given microstructures of the oxidation coating systems, to minimize the stress ,
th should be minimized

Results and discussion

With the given condition the Temperature dependent stress Ni(T) for 100 and 110
orientation at two different temperature such as To =280K ~ T1

References
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thermal barrier coatings ,J.Mater.Process.Technol.9293 (0) (1999)209216.
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barrier coatings,KeyEng.Mater.197(2001)199230.
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thermal barrier coatings,Scr.Mater.42(8)(2000)781787.
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