| Summary: | The present contribution gives an overview about recent research on a thermal barrier coating (TBC) system consisted of (i) an intermetallic MCrAlY-alloy Bondcoat (BC) applied by vacuum plasma spraying (VPS) and (ii) an Yttria Stabilised Zirconia (YSZ) top coat air plasma sprayed (APS) at Forschungszentrum Juelich, Institute of Energy and Climate Research (IEK-1). The influence of high temperature dwell time, maximum and minimum temperature on crack growth kinetics during thermal cycling of such plasma sprayed TBCs is investigated using infrared pulse thermography (IT), acoustic emission (AE) analysis and scanning electron microscopy. Thermocyclic life in terms of accumulated time at maximum temperature decreases with increasing high temperature dwell time and increases with increasing minimum temperature. AE analysis proves that crack growth mainly occurs during cooling at temperatures below the ductile-to-brittle transition temperature of the BC. Superimposed mechanical load cycles accelerate delamination crack growth and, in case of sufficiently high mechanical loadings, result in premature fatigue failure of the substrate. A life prediction model based on TGO growth kinetics and a fracture mechanics approach has been developed which accounts for the influence of maximum and minimum temperature as well as of high temperature dwell time with good accuracy in an extremely wide parameter range.
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