The objective of this study was to mimic the microstructure of MCrAlY coatings sprayed using HVOF (High Velocity Oxy-Fuel) processes by using an Air Plasma Spray (APS) process in order to improve oxidation and spallation life of MCrAlY APS coatings. Figure 1 shows the typical microstructures obtained when spraying bond coats using the (a) HVOF process, and (b) the APS process. The microstructur...

Low-temperature thermal cycling of plasma-sprayed zirconia coatings via curvature measurements revealed their in-plane non-linear behavior. This feature arises from the unique layered, porous and cracked morphology of thermal-sprayed ceramic materials. The nonlinear aspect can be quantified by a novel data interpretation procedure consisting of modified beam bending analysis and inverse analysi...

in this article, failure and fracture mechanisms in an aluminum alloy (which has been used in diesel internal combustion engines), with and without ceramic thermal barrier coatings, have been investigated under isothermal and non-isothermal fatigue loadings. in this research, the base material is an aluminum-silicon-magnesium alloy and the thermal barrier coating includes a metallic bond coat l...

Thermal barrier coating (TBC) systems are known to be extremely sensitive the applied thermo-mechanical loading in terms of both microstructure evolution and subsequent damage, leading final failure by ceramic top-coat layer spallation. The analysis relationship between mechanical behavior is limited scatter experimental results. Based on a typical TBC system for columnar top-coat, this study f...