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Effect of residual stresses on air plasma sprayed thermal barrier coatings
Surface and Coatings Technology 168 (2003) 291–299
Effect of residual stresses on air plasma sprayed thermal barrier coatings
a, a b
A. Nusair Khan *, J. Lu , H. Liao
a ´
LASMIS, Universite de Technologie de Troyes, BP 2060, 12 Rue de Marie Curie, Troyes, France
b ´ ´
LERMPS, Universite de Technologie de Belfort-Montbeliard, Belfort, France
Received 14 November 2002; accepted in revised form 13 January 2003
Abstract
Thermal barrier coating with a CoNiCrAlY bond coating and a 0.3 mm thick zirconia, (7% yttria stabilized) top coating were
air plasma sprayed onto a Hastelloy-X nickel based super alloy substrate coupons. Substrate preparation is a key initial step in
the production of quality thermal sprayed coatings. Grit blasting is usually used to roughen the substrate surface so that better
adhesion of the coating to the substrate is achieved. The effects of different grit blasting variables on the substrate surface
roughness were examined by using the Taguchi designed experimentation. The residual stress profiles were determined for a
different set of conditions by hole drill method. The Anstis et al. model was modified for the determination of indent toughness
of the substrate and bond coat interface. The results showed that the combination of grit size with distance and pressure during
the grit blasting were the most influential parameters. The adhesion of the coatings increases with increase of substrate roughness
up to certain limits and th
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