Relationship between internal stress distribution and microstructure in a suspension-sprayed thermal barrier coating with a columnar structure

Yamazaki, Yasuhiro*; Shinomiya, Keisuke*; Okumura, Tadaharu*; Suzuki, Kenji*; Shobu, Takahisa  ; Nakamura, Yuiga*

The suspension plasma spray (SPS) technique has attracted attention because of its various microstructures, which can be achieved by mixing submicron spray particles with a solvent to form a suspension. Thermal barrier coatings (TBCs) with a columnar structure, which might achieve high strain tolerance, can be obtained using the SPS technique. In this study, the internal stress distribution of the SPS-TBC with different columnar structures was evaluated by hybrid measurement using high-energy synchrotron X-ray diffraction analysis and laboratory low-energy X-rays. The effect of microstructure on the internal stress distribution of the SPS-TBC was discussed on the basis of the experimental results. In addition, the in-plane internal stress was decreased by decreasing the column diameter. The thin columnar microstructure of the SPS-TBC has superior strain tolerance. The internal stresses in the column of the SPS-TBC are periodic decrements caused by stress relaxation in porous layers.