Thermal Barrier Coatings in burner rig experiment analyzed through LAser Shock for DAmage Monitoring (LASDAM) method

This study investigates failure mechanisms in a typical thermal barrier coating (TBC) system comprising an EB-PVD columnar top coat, an aluminide bond coat, and a Ni-based single crystal superalloy substrate, simulating gas turbine operating conditions using a burner rig. TBC degradation, initiated by interfacial defects from the LASAT method, was studied during thermal gradient cycling under fast and slow cooling. In-situ optical and infrared imaging, along with ex-situ SEM cross-sectional analysis, monitored failure mechanisms. The Laser Shock for Damage Monitoring (LASDAM) technique provided insights into gradient and cooling rate impacts on columnar TBC damage. Results showed significant effects of cooling rate on delamination and localized failure at blister sites, with LASDAM revealing significant overheating at damage sites. Analysis included full-field temperature and damage assessment, emphasizing blister-driven delamination under severe thermal gradients. Discussion focused on elastic stored energy effects, noting that fast cooling induced transient conditions where reversed temperature gradients increased damage, limiting TBC lifespan.