Fracture mechanism maps for thermal barrier coatings subjected to single foreign object impact

To further understand the erosion mechanism of the electron beam physical vapor deposited thermal barrier coatings, the failure mechanism diagrams with different parameters were established by finite element simulations. The effects of various parameters on foreign object erosion were discussed. The location and type of coating cracks under different conditions were predicted. It was found that the possibility of crack nucleation increases with the increase of the particle velocity, particle radius and impact angle. Compared to the structural and material parameters of thermal barrier coatings, the erosion particle parameters (particle velocity, particle radius and impact angle) have a greater effect on the coating failure. All of these results give corresponding suggestions and advices for process optimization of thermal barrier coatings.