Effect of sintering on stress distribution of thermal barrier coatings for high temperature blade

In the process of long-term high temperature service, thermal barrier coatings (TBCs) will inevitably be sintered, leading to pores healing and porosity decline, which will affect the microstructure and the stability of mechanical properties of TBCs. To understand the relationship between the microstructural changes of sintered TBCs and the mechanical properties, in this work, the cross-sectional microstructure of TBCs at different sintering times were investigated by scanning electron microscopy (SEM). After calculating the porosity and pore size distribution, two-dimensional (2D) numerical models were developed for five different porosities (16% to 12%) by an improved reconstruction method with layer-by-layer labeling. Based on the results of finite element (FE) analysis after thermal cycling, it was found that the coating's irregular pore structures lead to stress concentration, which affects the mechanical properties of the coating to a great extent. For the whole TC layer, the level of stresses increases and the absolute value of maximum stress augments significantly by 46% associated with the doubled increase of stress concentration areas with the densification of coating. For the local areas of TC layer, the changes in pore morphology led to a more complex variation in local stress fields. At the TC/BC interface, the Mises stress level tends to increase with decreasing porosity during sintering. At the TC surface, coatings with lower porosities cause higher stresses near this region. The insights gained from the numerical results contribute to a better understanding of the failure behavior of real TBCs systems and help to further remedy the deficiencies and difficulties of the experimental work.