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Numerical Investigation into the Effect of Splats and Pores on the Thermal Fracture of Air Plasma-Sprayed Thermal Barrier Coatings

Krishnasamy, J., Ponnusami, S. A. ORCID: 0000-0002-2143-8971, Turteltaub, S. & van der Zwaag, S. (2019). Numerical Investigation into the Effect of Splats and Pores on the Thermal Fracture of Air Plasma-Sprayed Thermal Barrier Coatings. Journal of Thermal Spray Technology, 28(8), pp. 1881-1892. doi: 10.1007/s11666-019-00949-y


The effect of splat interfaces on the fracture behavior of air plasma-sprayed thermal barrier coatings (APS-TBC) is analyzed using finite element modeling involving cohesive elements. A multiscale approach is adopted in which the explicitly resolved top coat microstructural features are embedded in a larger domain. Within the computational cell, splat interfaces are modeled as being located on a sinusoidal interface in combination with a random distribution of pores. Parametric studies are conducted for different splat interface waviness, spacing, pore volume fraction and fracture properties of the splat interface. The results are quantified in terms of crack nucleation temperature and total microcrack length. It is found that the amount of cracking in TBCs actually decreases with increased porosity up to a critical volume fraction. In contrast, the presence of splats is always detrimental to the TBC performance. This detrimental effect is reduced for the splat interfaces with high waviness and spacing compared to those with low waviness and spacing. The crack initiation temperature was found to be linearly dependent on the normal fracture properties of the splat interface. Insights derived from the numerical results aid in engineering the microstructure of practical TBC systems for improved resistance against thermal fracture.

Publication Type: Article
Additional Information: © The Author(s) 2019. Open Access.This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (, which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.
Publisher Keywords: cohesive elements, fracture, porosity, splats, thermal barrier coatings
Subjects: T Technology > TJ Mechanical engineering and machinery
Departments: School of Science & Technology > Engineering
SWORD Depositor:
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