Finite element simulation of tensile bond strength of atmospheric plasma spraying thermal barrier coatings

►Finite element models based on the realistic microstructural images of TBCs. ►The fracture tensile stress of dense YSZ is 215 MPa by MBD specimens. ►Modeling microcracks growth of TBCs during the tensile process. ►The tensile bond strength of simulation results is 40 MPa by Weibull analysis.