Thermal cycling behavior of plasma-sprayed thermal barrier coatings with various MCrAIX bond coats

The influence of bond coat composition on the spallation resistance of plasma-sprayed thermal barrier coatings (TBCs) on single-crystal Rene N5 substrates was assessed by furnace thermal cycle testing of TBCs with various vacuum plasma spray (VPS) or air plasma-spray (APS) MCrAIX (M = Ni and/or Co; and X = Y, Hf, and/or Si) bond coats. The TBC specimens with VPS bond coats were fabricated using identical parameters, with the exception of bond coat composition. The TBC lifetimes were compared with respect to MCrAIX composition (before and after oxidation testing) and MCrAIX properties (surface roughness, thermal expansion, hardness, and Young's modulus). The average TBC spallation lifetimes varied significantly (from 174 to 344 1 h cycles at 1150°C) as a function of bond coat composition. Results suggested a relationship between TBC durability and bond coat thermal expansion behavior below 900°C. Although there were only slight differences in their relative rates of cyclic oxidation weight gain, VPS MCrAIX bond coats with better oxide scale adhesion provided superior TBC lifetimes.