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Mechanism of spallation in platinum aluminide/electron beam physical vapor-deposited thermal barrier coatings

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Abstract

The spallation failure of a commercial thermal barrier coating (TBC), consisting of a single-crystal RENE N5 superalloy, a platinum aluminide (Pt-Al) bond coat, and an electron beam-deposited 7 wt pct yttria-stabilized zirconia ceramic layer (7YSZ), was studied following cyclic furnace testing. In the uncycled state and prior to deposition of the ceramic, the Pt-Al bond-coat surface contains a cellular network of ridges corresponding to the underlying bond-coat grain-boundary structure. With thermal cycling, the ridges and associated grain boundaries are the sites of preferential oxidation and cracking, which results in the formation of cavities that are partially filled with oxide. Using a fluorescent penetrant dye in conjunction with a direct-pull test, it is shown that, when specimens are cycled to about 80 pct of life, these grain-boundary regions show extensive debonding. The roles of oxidation and cyclic stress in localized grain boundary region spallation are discussed. The additional factors leading to large-scale TBC spallation are described.

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Authors and Affiliations

  1. Department of Metallurgy and Materials Engineering, USA

    Maurice Gell (Professor-in-Residence) & Krishnakumar Vaidyanathan (Graduate Assistant)

  2. Department of Mechanical Engineering, the University of Connecticut, 06269, Storrs, CT

    Brent Barber (Graduate Assistant) & Eric Jordan (Professor)

  3. Institute of Materials Science, the University of Connecticut, 06269, Storrs, CT

    Jiangtian Cheng (Postdoctoral Fellow)

Authors
  1. Maurice Gell
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  2. Krishnakumar Vaidyanathan
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  3. Brent Barber
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  4. Eric Jordan
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  5. Jiangtian Cheng
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Gell, M., Vaidyanathan, K., Barber, B. et al. Mechanism of spallation in platinum aluminide/electron beam physical vapor-deposited thermal barrier coatings. Metall Mater Trans A 30, 427–435 (1999). https://doi.org/10.1007/s11661-999-0332-1

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