Crack Morphology in a Columnar Thermal Barrier Coating System

Abstract

Ceramic layers are used as thermal barrier coatings (TBCs) on metallic substrates. During thermal transients, the thermal expansion mismatch between coating and substrate drives failure of the TBC mainly by interfacial cracking. Laser Shock Adhesion Test (LASAT) provides stresses at the ceramic/metal interface enabling controlled interfacial cracking. For achieving a clear understanding of the influence of local morphology on interfacial toughness, this study aims at characterizing the 3D morphology of a crack at the interface between metal and an EB-PVD TBC having a columnar structure. Cracks were produced by LASAT and documented further in SE and BSE image stacks collected simultaneously during subsequent slice and view operations using a focus ion beam (FIB) and a scanning electron microscope (FIB slice & view). The segmented 3D data gives clear understanding of the columnar structure of the ceramic and of the interaction between the crack and the TBC microstructure.