Production, characterization, microstructure study and comparison of thermal shock behavior of two-layer and functionally graded thermal barrier coatings

Thermal barrier coatings are used to insulate the components in the hot turbine parts to increase the working temperature and efficiency of these components. In this study, conventional and functionally graded thermal barrier coatings of NiCrAlY / YSZ were applied by plasma spraying on Hastelloy-x. The specimens were subjected to thermal shock with a defined cycle. The coatings were characterized using optical microscope, Scanning Electron Microscopy (SEM), Energy Dispersive x-ray Spectrometry (EDS), map analysis and X-Ray Diffraction (XRD). Moreover, thermal shock resistance of the coatings was determined. The thermal shock stress was measured by a new method. In this research, nano-indentation stress measurement method was used to measure the residual stress in thermal barrier coatings. The results of scanning electron microscopy analysis showed that microstructure, porosity and chemical composition changed gradually through the functionally graded coating. Surveying the surface of the samples after applying thermal shock showed that the separation of layers in the two-layer thermal barrier coatings occurred more than the graded coatings. The results of stress measurement by nano-indentation method indicated that the designed method for measuring stress, in contrast to other conventional methods, can measure stresses along the coating depth with acceptable accuracy, without damaging the sample.