Structural optimization for the thermal conductivity and thermal cycling behavior in thermal barrier coatings and analysis of thermomechanical properties by computational investigation

The microstructure affects the service life and performance in thermal barrier coatings (TBCs). A series of yttria-stabilized zirconia (YSZ) coatings with embedded micro-agglomerated particles (EMAP) are prepared using plasma co-spraying technology. The thermal conductivity and thermal cycling behavior between EMAP coatings with various transfer speeds and traditional YSZ coating are explored. Experimental and finite element simulations are conducted to explore the effect of pore structure characteristics on the thermomechanical properties of coatings. Results show that the thermal conductivity of EMAP coatings is lower than that of traditional YSZ coating, with EMAP coating deposited at 200 mm/s transfer speed having the lowest thermal conductivity. The thermal cycling life of EMAP coatings at transfer speeds of 600 mm/s and 800 mm/s is improved by 20.00 % and 58.33 % compared to traditional YSZ coating. This paper suggests the mechanism of excellent thermal insulation and service life of porous coatings.