Through-thickness determination of phase composition and residual stresses in thermal barrier coatings using high-energy X-rays

High-energy X-rays were used to determine the local phase composition and residual stresses through the thickness of as-sprayed and heat-treated plasma-sprayed thermal barrier coatings consisting of a NiCoCrAlY bond coat and an yttria-stabilized zirconia (YSZ) topcoat produced with through-thickness segmentation cracks. The as-sprayed residual stresses reflected the combined influence of quenching stresses from the plasma spray process, thermal expansion mismatch between the topcoat, bond coat and substrate, and stress relief from the segmentation cracks. Heat treatments led to the formation of a thermally grown oxide (TGO) which was in compression in the plane, as well as relief of quenching stresses and development of a stress gradient in the YSZ topcoat. The high-energy X-ray technique used in this study revealed the effects that TGO and segmentation cracks have on the in-plane stress state of the entire coating.