EIIect oI bond coat nature and thickness on mechanical characteristic

and contact damage oI zirconia-based thermal barrier coatings

Jae-Young Kwon
a
, Jae-Hyun Lee
a
, Yeon-Gil Jung
a,
, Ungyu Paik
b
a
School of Nano and Advanced Materials Engineering, Changwon National Universitv, 9 Sarim-dong, Changwon, Kvungnam 641-773, Republic of Korea
b
Division of Advanced Materials Science Engineering, Hanvang Universitv, 17 Haengdang-dong, Seongdong-gu, Seoul 133-791, Republic of Korea
Received 28 March 2006; accepted in revised Iorm 27 July 2006
Available online 7 September 2006
-
Mechanical characterization and contact damage oI zirconia-based thermal barrier coatings (TBCs) have been investigated using
nanoindentation and Hertzian indentation tests. Two types oI TBC systems with diIIerent bond coat thicknesses oI 60+20 and 280+20 m were
prepared using two diIIerent processes: air plasma spraying (APS) and high-velocity oxygen Iuel (HVOE). Top coats were coated onto each bond
coat using the APS process. The TBC system with the bond coat Iormed using the HVOE process shows a step-like decrease in mechanical
properties on passing Irom the substrate to the top coat, and the bond coat Iormed using the HVOE process indicates higher values oI E and H
than that prepared using the APS process. The mechanical properties directly aIIect indentation stressstrain curves oI the TBC systems, and the
stressstrain curves oI the TBC system with the APS bond coat are signiIicantly lower than those with the HVOE process. The bond coat
thickness plays an important role in limiting the eIIect oI damage, indicating that the thin bond coat enhances contact damage and transmits the
damage to the substrate, whereas the thick bond coat limits the damage to within the bond coat at a relatively low load oI P500 N. As the
indentation load and the number oI cycles increase, the contact damage is enhanced and becomes more severe in the TBC system with the APS
bond coat. The Iracture modes in the top coat and between the top coat and the bond coat oI the TBC system are dependent on the bond coat
nature, including the accumulation oI damage and its development at high loads oI 1000 and 1500 N. The TBC system with the APS bond coat
shows a bigger and more intensive damage region.
2006 Elsevier B.V. All rights reserved.
Kevwords. Bond coat; Plasma spraying; High-velocity oxyIuel (HVOE); Zirconium oxide; Thermal barrier coatings (TBCs)

Zirconia-based thermal barrier coatings (TBCs) on metal
alloy substrates are widely used in gas turbines in power
generation, and particularly on the Iirst stage oI these gas
turbines. Among the various Iabrication methods used Ior TBCs
to protect gas turbine blades Irom oxidation and corrosion at
high temperatures, the air plasma spraying (APS) process and
the electron beam physical vapor deposition (EB-PVD) process
have been particularly widely used |18|. APS technology is
preIerred commercially in contrast to the use oI complex and
expensive EB-PVD equipment, even though EB-PVD coatings
have superior properties, such as better corrosion resistance,
bond strength, and surIace roughness |9,10|.
A bond coat is usually employed in TBCs to improve their
structural eIIectiveness and the adhesion between the zirconia-
based top coat and the superalloy substrate. In addition, the bond
coat plays an important role in protecting the substrate Irom
oxidation, having the thickness oI 75150 m|1114|. The bond
coat is usually coated onto the substrate using the APS process
because oI economic considerations, even though a high number
oI deIects, such as pores and microcracks, can occur. However, an
increase in the working temperature oI a turbine can lead to
service limits oI the TBCs having a bond coat prepared using the
APS process. ThereIore, mechanical properties and oxidation
resistance oI a bond coat in the TBC system should be enhanced
and improved to elongate their liIetime.
Recently many techniques Ior Iorming a bond coat have been
developed, such as vacuumplasma spraying (VPS), low-pressure
plasma spraying (LPPS), high-Irequency pulse detonation
(HEPD), and high-velocity oxygen Iuel (HVOE) spraying
SurIace & Coatings Technology 201 (2006) 34833490
www.elsevier.com/locate/surIcoat
Corresponding author. Tel.: 82 55 289 7201; Iax: 82 55 262 6486.
E-mail address. jungygchangwon.ac.kr (Y.-G. Jung).
0257-8972/$ - see Iront matter 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.surIcoat.2006.07.240
|11,1519|. Among these preparation techniques, HVOE spray-
ing provides a good microstructure and better adhesive strength,
and has low operating coats compared with the APS process,
resulting in its replacing the APS process as the Iabrication
method Ior Iorming a bond coat in gas turbines. ThereIore, there is
a need to estimate and understand the mechanical characteristic
and Iracture behavior or damage mode in TBC systems having
bond coats prepared using diIIerent processes, such as the APS
and HVOE processes, which is essential to improving the
reliability and liIetime perIormance oI these TBC systems.
The mechanical properties, such as elastic modulus, E, and
hardness, H, oI TBCs have been measured using various
techniques and reported in the literature, with the Iocus being
on zirconia-based top coats |2023|. However, the reported
values are inconsistent and dependent on the deIect density in the
top coat, such as pores and microcracks, and on geometric Iactors
in the measuring method employed. The Iracture behavior and
materials response oI layered-structure materials having a plasma-
sprayed coating layer Ior contact environments have been
developed and well described through model studies, especially
in the works oI Lawn et al. |2428|, using the Hertzian contact
technique, but the behavior oI real TBC systems has not. The
simple Hertzian tests provide quantitative data on indentation
stressstrain relationship, and provide qualitative inIormation on
the Iracture modes and the evolution oI damage Irom the
bonded-interIace technique |24,25|.
In this work, the mechanical properties and contact damage
oI TBCs with diIIerent bond coats have been evaluated using
nanoindentation and Hertzian indentation tests. The relationship
between the mechanical properties and the contact damage is
discussed, and the advantages oI the HVOE and APS processes
Ior Iorming a bond coat in the cyclic contact environments are
highlighted.

2.1. Materials and preparation
Anickel-based superalloy (GTD-111 developed by the General
Electric Company, USA) was used as a substrate. Elat rectangular
test samples were machined Irom the shrunken section oI a Iully
heat-treated GTD-111 turbine blade using an electro-discharge
machining process. Details oI the substrate have been described
elsewhere in the literature |20|. The samples were ground and
polished to remove the recast layer. Two types oI bond coats were
chosen to compare the eIIect oI the bond coat nature and its
thickness on the mechanical properties and contact damage in
zirconia-based TBCs. One sample was Iormed using the HVOE
process with powdered CoNiCrAlYalloy (AMDRTY 4195,
Sulzer Metco HoldingAG, Switzerland), and the other coatingwas
Iormed using the APS process with powdered CoNiCrAlY
alloy (AMDRY 995C, Sulzer Metco Holding AG, Switzerland).
Bond coats with two diIIerent thicknesses oI 60+20 and 280+
20 m were prepared. Top coats were Iormed using powdered
zirconia (ZrO
2
) containing 8 wt. oI yttria (Y
2
O
3
) (METCO
204NS-G, Sulzer Metco Holding AG, Switzerland), which was air
plasma-sprayed to a thickness oI 230+20 monto the bond coats.
The Iabrication parameters oI the APS and HVOE processes are
shown in Table 1. These are recommended by the manuIacturer.
2.2. Characteri:ation
The as-prepared samples were sectioned and given a Iinal
polish using 1 m diamond paste Ior characterization. To
remove any residual stress induced by the grinding and
polishing operations, the samples were Iinally polished with a
10 nm silica (SiO
2
) colloidal solution. Nanoindentation tests
were conducted on each component oI the TBC systems to
determine the values oI E and H using a nanoindentor
(Nanoinstruments, MTS Systems Corp., Eden Prairie, USA)
with a Berkovich tip (tip radius 100 nm), using the continuous
stiIIness measurement (CSM) option. The data were selected
aIter indentation oI up to 2000 nm depth. Minimum 10
indentations were conducted on each layer-top coat, bond coat,
and substrate Ior minimum three samples.
Indentation tests using an Instron mechanical properties testing
machine (Model 1122, Instron Corp., Canton, MA, USA)
employing tungsten carbide (WC) spheres with radius r1.98
9.52 mmwere conducted on the polished top surIaces oI the TBCs
with diIIerent types and thicknesses in the bond coat, as well as on
the bond coat/substrate without the top coat and on the substrate
alone, to obtain indentation stressstrain curves |2428|. The
values oI Hand E Ior a WCindenter used in this study are 19 GPa
and 614 GPa, respectively |27|. The test surIaces were Iirst
polished with 1 mdiamond paste and were then re-polished with
a 10 nm silica (SiO
2
) colloidal solution. AIter indentation, the
residual contact radius, a, Ior sphere radius, r, at each applied load
was measured, and then indentation stress (p
o
P/ a
2
) as a
Iunction oI indentation strain, a/r |26,27| was computed. A thin
gold coating was deposited on the surIace beIore indentation to
help measure the actual contact area at relatively low loads.
The bonded-interIace samples polished on both sides were
prepared by adhering with cyano-acrylate-based adhesive
(Loctite Co., Newington, CT, USA), and then clamped
|24,25|. The interIace thickness was below 5 m. The top
surIace was slightly polished, and Iinished oII using a 1 m
diamond paste beIore clamping. As reIerence specimens, bond
coat/substrate samples without the top coat were also prepared
Table 1
Starting materials and Iabrication parameters oI the APS and HVOE processes
HVOE
(Ior bond coat)
APS
(Ior bond coat)
APS
(Ior top coat)
Material AMDRY 4195 AMDRY 99C METCO 204NS-G
Gun JK 3000 Metco 9MB Metco 9MB
Primary and
secondary gas
O
2
and H
2
Ar and H
2
Ar and H
2
Powder carrier gas
(psi)
Argon (150+2) Nitrogen (40+2) Argon (60+2)
Eeed rate (g/min) 35+5 44+5 60+5
Gun-to-work
distance (in.)
9+0.5 3+0.5 4+0.5
Gun traverse
speed (mm/s)
3+1 5+1 5+1
3484 J.-Y. Kwon et al. / Surface & Coatings Technologv 201 (2006) 34833490
using the HVOE and APS processes. Single-cycle indentations
were perIormed on the top surIaces oI the samples using a WC
spherical indenter with radius r 3.18 mm up to a peak load oI
P1500 N. Normally, the reported compressive residual
stresses on thermal barrier coated high pressure turbine blade
are 2.42.8 GPa Ior as-prepared and 2.33.1 GPa aIter service,
depending on surIace geometry oI thermally grown oxides |29|.
ThereIore, we have adjusted the indenter size (WC sphere) Ior
the contact tests, based on indentation stressstrain results. In
addition, multi-cycle indentations at a peak load oI P500 N
were carried out up to 10
6
cycles, and P1000 N up to 10
5
cycles, at a Irequency oI 10 Hz using an Instron cyclic testing
machine (Model 8500, Instron Corp., Canton, MA, USA). The
indentations were conducted along the trace oI the bonded
interIace on the top surIace. The indented specimens were then
separated and cleaned, and viewed using an optical microscope.
All experiments were perIormed in air at room temperature.
-- ---
3.1. Mechanical properties
The elastic modulus, E, and hardness, H, oI each component
in the TBC systems, which were measured in the nanoindenta-
tion tests, are shown in Table 2. The values oI E in the TBC
system with the HVOE bond coat show a step-like decrease on
passing Irom the substrate to the top coat, whereas the values oI
E in the TBC system with the APS bond coat show a sudden
decrease on passing through the interIace between the substrate
and the bond coat. The values oI H also are not much changed,
having a lower value in the bond coat than in the top coat in the
TBC system with the APS bond coat.
In this study, the changes in E and H at the interIace and the
dependence on the bond coat thickness are not considered. The
relatively porous microstructure oI the APS bond coat leads to
the lower values oI the E and H in the bond coat. The values oI
E are changed more dramatically than the values oI H,
indicating that the stiIIness is closely related to the microstruc-
ture and/or deIects, such as pores and microcracks |21|. A
cracking or delamination at the interIace between the bond coat
and the top coat will be expected to occur in the indentation tests
as the diIIerence in the values oI E and H increases, because oI
the elastic/plastic mismatch stress present |20,26|.
3.2. Indentation stressstrain curves
Eig. 1 shows indentation stressstrain curves Ior the TBC
system with the HVOE bond coat and the HVOE bond coat/
substrate system without the top coat as a Iunction oI the bond
coat thickness, and Ior the substrate alone. The system becomes
soIter as the bond coat and the top coat are Iormed on the
substrate. This result can be expected Irom the values oI E and
H in Table 2. The stressstrain curves are not aIIected much by
a change in the bond coat thickness, except in the lower and
higher stress regions Ior the bond coat/substrate and the top
coat/bond coat/substrate systems, respectively. In the bond coat/
substrate system, a compression stress applied to the thin bond
coat is constrained in the early stages by the harder substrate,
resulting in a smaller contact area in the lower stress region
compared with the case oI the thick bond coat. In the top coat/
bond coat/substrate system, the bond coat or the substrate reacts
to the compression stress in the higher strain region, resulting in
the same response observed Ior the porous microstructure oI the
top coat versus the compression stress in the lower strain region.
Consequently, the top coat and the bond coat in the TBC
systems result in a soItening oI the substrate, with a minor
eIIect oI the bond coat thickness on the soItening.
The stressstrain curves Ior the APS bond coat are much
lower than those prepared using the HVOE process, and this is
especially so Ior the thick bond coat (Eig. 2). DeIects, such as
pores and microcracks, are accumulated in the bond coat as the
bond coat thickness is increased. ThereIore, the stressstrain
curves in the bond coat/substrate system with the APS bond
coat show a dramatic change with increasing the bond coat
thickness. It is interesting to note that the stressstrain curve oI
the top coat/bond coat/substrate system is located below that oI
the bond coat/substrate system, even though the values oI E and
H are slightly higher. The nanoindentation tests provide the
values oI E and H in localized regions, which lowers any eIIect
oI changes in the microstructure. Previous studies have
indicated that the global and local properties oI TBCs show a
large scatter in the observed data |21,23,30|. The inIluence oI
the hard substrate can be considered as another possibility,
because the value oI E oI the substrate is much higher than those
oI the top and the bond coat. As a result, the properties oI the
Table 2
Elastic modulus, E, and hardness, H, oI the substrate, bond coats, and top coat
measured using the nanoindentation technique
Properties Substrate
(GTD 111)
HVOE
(Ior bond coat)
APS
(Ior bond coat)
APS
(Ior top coat)
E (GPa) 232+28 155+21 90+35 94+32
H (GPa) 5.6+0.4 5.0+0.8 3.2+0.9 4.2+0.9
The bond coats were prepared using diIIerent processes: HVOE and APS.
Eig. 1. Indentation stressstrain curves Ior substrate, bond coat/substrate, and
top coat/bond coat/substrate in the TBC system with the bond coat being
prepared using the HVOE process. The data were obtained using WC spheres
with r 1.989.52 mm. The solid curves are empirical data Iits.
3485 J.-Y. Kwon et al. / Surface & Coatings Technologv 201 (2006) 34833490
thermal barrier top coat make the system soIter, and this is
independent oI the bond coat type. In addition, the stressstrain
curves oI the bond coat/substrate system with the APS bond
coat are dependent on the bond coat thickness. However, the
relatively hard bond coat Iormed by the HVOE process
diminishes the soItening eIIect and the eIIect oI the bond coat
thickness on the stressstrain curves, which is consistent with
the observed mechanical properties.
3.3. Contact damages
The eIIect oI the bond coat thickness and the top coat in the
TBC system with the HVOE bond coat on the evolution oI
contact damage is shown in Eig. 3, which shows micrographs oI
the subsurIace damage aIter cyclic indentation tests carried out
at a peak load oI P500 N Ior n1, 10
5
, and 10
6
, using a WC
spherical indenter with r 3.18 mm. The damage in the
substrate is easily developed Irom a single indentation in the
TBC system with the thin bond coat, which is extended to a
depth limited by the coat. The top coat is disintegrated as the
number oI cycles is increased. Meanwhile, the TBC system with
the thick bond coat shows a damage zone contained within the
bond coat, which is not transmitted to the substrate, even Ior a
high number oI cycles, n10
6
. The contact diameter is not
much aIIected by diIIerent bond coat thickness, except when a
higher number oI cycles, n10
6
, is applied. The subsurIace
damage indicates that the thicker bond coat is more eIIicient in
protecting the substrate Irom contacts than the thinner bond
coat, although indentation stressstrain curves shown in Eig. 1
are similar. The system without the top coat, i.e., the bond coat/
substrate system, also shows a well-deIined damage zone, with
Eig. 3. Contact damages oI top coat/bond coat/substrate and bond coat/substrate, at peak load P500 N and Irequency 10 Hz, Ior n1, 10
5
, and 10
6
. (a) and (b) are the
top coat/bond coat/substrate Ior bond coat thicknesses oI d 60 and 280 m, respectively, and (c) is the bond coat/substrate Ior bond coat thickness oI d 280 m. The
contact diameter is shown by arrows. The bond coats were prepared using the HVOE process. Indentation was carried out using a WC sphere with r 3.18 mm.
Eig. 2. Indentation stressstrain curves Ior bond coat/substrate and top coat/bond
coat/substrate in the TBC system with the bond coat being prepared using the
APS process. The data were obtained using WC spheres with r 1.989.52 mm.
The solid curves are empirical data Iits. The dashed curve is the substrate
material shown in Eig. 1, and is included Ior comparison.
3486 J.-Y. Kwon et al. / Surface & Coatings Technologv 201 (2006) 34833490
a minor damage occurring in the substrate. The contact diameter
oI the bond coat/substrate system is independent oI the number
oI cycles, showing a similar contact diameter in all cases.
However, the contact diameter oI the bond coat/substrate
system is smaller than those oI the top coat/bond coat/substrate
systems, consistent with the data shown in Eig. 1, indicating that
the top coat is soIter than the bond coat. The damage zone
Iormed in the bond coat is not extended, only showing damage
accumulation within the bond coat, whereas the damage zone in
the thinner bond coat is well deIined within the substrate (results
not shown), and this damage is extended into the substrate with
increasing the number oI cycles.
The subsurIace damage oI the TBC system with the APS
bond coat is shown in Eig. 4. The test condition was same with
the case oI Eig. 3. In comparison with Eig. 3(c), the damage
zone in the bond coat/substrate system reaches the interIace Ior
a single indentation, and this is accumulated and is extended
with increasing the number oI cycles. An intensive damage zone
is developed because oI the soIt bond coat. As mentioned above
in the discussion on indentation stressstrain curves, the soIter
bond coat will transIer the stress to the substrate and damage the
substrate. The top coat acts as a protective layer in a contact
environment, showing less damage in the bond coat and no
damage in the substrate compared with the case without the top
coat. The contact diameter oI the TBC system with the top coat
is larger than that oI the TBC system without the top coat,
indicating that the hard substrate restrains the development oI
contact damage. This result is consistent with the stressstrain
curves shown in Eig. 2.
The evolution oI damage Ior each case is shown in Eigs. 5 and 6
when the indentation load is increased to P1000 N. Eig. 5 shows
micrographs Ior the TBC system with the HOVE bond coat. The
damage zone is extended to the substrate to a limited depth Ior a
single indentation, and this is independent oI the top coat. The
damage zones in both the bond coat and the substrate and the
contact diameter are much smaller than those oI the APS process
(Eig. 6). Also, the bending oI the bond coat is constrained in the
HVOE process. This is due to better mechanical properties
conIerred by the HVOE process, which is consistent with the
stressstrain data. AIter the cyclic tests, the damage zones and
contact diameter oI the TBC system with the HVOE bond coat are
smaller than those oI the TBC system with the APS bond coat,
indicating that the values oI EandHoI the APS bond coat aIIect the
development oI contact damage and the accumulation oI damage.
ThereIore, the HVOE bond coat is eIIective in improving the
damage tolerance oI the TBCs system.
In high magniIication micrographs shown in Eig. 7, the
diIIerence between the HVOE and APS processes is particularly
apparent. In the TBC system with the HVOE bond coat, crack or
delamination at the interIace oI the top coat and the bond coat is
apparent, along with a small damage zone in the bond coat.
Meanwhile, in the TBC system with the APS bond coat, the
Iracture is developed within the top coat and not the interIace.
The diIIerence in preparation method oI the top coat and the
bond coat in the TBC system with the HVOE bond coat aIIect
the Iracture behavior at the interIace between the top coat and
the bond coat, according to the diIIerent Iormation behavior Ior
each coat. In addition, the damage zone is smaller than that
Eig. 4. Contact damages oI (a) bond coat/substrate and (b) top coat/bond coat/ substrate with bond coat thickness oI d 280 m prepared using the APS process, at
peak load P500 N and Irequency 10 Hz, Ior n1, 10
5
, and 10
6
. The contact diameter is shown by arrows. Indentation was carried out using a WC sphere with
r 3.18 mm.
3487 J.-Y. Kwon et al. / Surface & Coatings Technologv 201 (2006) 34833490
observed Ior the APS process. However, there are no cone-like
cracks on the top coat created in the dense and brittle material or
vertical cracks at the interIace caused by the soIt substrate |28|.
The Iracture mode in the top coat is also dependent on the bond
coat type. The Iracture oI the top coat in the TBC system with
the harder bond coat (prepared using the HVOE process) arise
Eig. 5. Contact damages oI (a) bond coat/substrate and (b) top coat/bond coat/ substrate with bond coat thickness oI d 280 m prepared using the HVOE process, at
peak loads P1000 N and Irequency 10 Hz, Ior n1, 10
3
, and 10
5
. The contact diameter is indicated by arrows. Indentation was carried out a WC sphere with
r 3.18 mm.
Eig. 6. Contact damages oI (a) bond coat/substrate and (b) top coat/bond coat/ substrate with bond coat thickness oI d 280 m prepared using the APS process, at
peak loads P1000 N and Irequency 10 Hz, Ior n1, 10
3
, and 10
5
. The contact diameter is indicated by arrows. Indentation was carried out using a WC sphere with
r 3.18 mm.
3488 J.-Y. Kwon et al. / Surface & Coatings Technologv 201 (2006) 34833490
because oI the compression on the top coat with less crack
coalescence, whereas the Iracture in the TBC system with the
soIter bond coat (prepared using the APS process) is due to the
mixed mode oI compression on the top coat and bending in the
bond coat with larger and more open cracks.
Contact damage under a high load P1500 N is shown in
Eig. 8, Ior the TBC systems with diIIerent bond coats Iormed
using the HVOE and APS processes (Eigs. 8(a) and 8(b),
respectively). The damage modes in the bond coat and the
substrate oI the TBC system with the HVOE bond coat Iollow
the mechanical properties oI each coat and show a gradual
transition on passing Irom the top coat to the substrate. The
bond coat should Iorm a protection layer against impacts.
However, the bond coat with similar mechanical properties to
the top coat enhances any damage in the substrate, showing a
bigger damage zone in the bond coat.
This study shows that a relatively porous bond coat will be
advantageous Irom the viewpoint oI energy absorption,
especially at low impact loads Ior P 500 N or Ior a lower
number oI cycles. However, this structural advantage is
diminished at higher loads above P1000 N or Ior a higher
number oI cycles, as this enhances the damage and so expands
the damage zone in both the bond coat and the substrate. In view
oI the liIetime oI the system, a porous structure lessens damage
tolerance and accelerates the Iailure oI the system, even though
it has been reported that damage accumulated on the top coat or
the bond coat can improve the thermal protection oI the
substrate |31|. Using the HVOE process Ior the bond coat is the
better choice Ior improving damage tolerance and Ior protecting
the substrate in TBC systems. In addition, a thicker bond coat
has to be applied to a TBC system to protect the substrate Irom
impacts. However, a dense microstructure and higher mechan-
ical properties lead to a higher degree oI stiIIness, resulting in
low thermo-mechanical stability because oI high residual stress
and a low strain tolerance during service at high temperature
|23,32|. ThereIore, the damage modes and mechanical
properties oI the TBC system aIter thermal Iatigue need to be
investigated to conIirm the eIIect oI the bond coat on contact
damage and to determine the best conditions Ior the bond coat in
TBC systems in a real application. These studies are now in
progress and will be reported on in a later publication.
In this work, two types oI TBCs with diIIerent bond coats
prepared using the HVOE and APS processes were prepared to
evaluate the eIIect oI the bond coat nature, i.e., HVOE or APS
process derived with thicknesses oI 60+20 and 280+20 m, on
Iracture behavior and contact damage in air plasma-sprayed
zirconia-based TBCs. The mechanical properties oI each
componentthe top coat, bond coat and substratein the TBC
systems were measured using nanoindentation tests to obtain
the elastic modulus, E, and hardness, H. The Hertzian
indentation tests provide indentation stressstrain curves Ior
each component and TBCs with diIIerent natures and
thicknesses in the bond coat. The mechanical properties oI the
bond coat are dependent on the preparation method and are
consistent with indentation stressstrain curves. The bonded-
Eig. 8. Contact damages oI top coat/bond coat/substrate systems with bond coat
thickness oI d 280 m prepared using the (a) HVOE and (b) APS processes.
Indentation was carried out using a WC sphere with r 3.18 mm and
P1500 N, Ior n1. The solid and dotted lines indicate the damaged regions
in the bond coat and the substrate, respectively.
Eig. 7. High magniIication optical micrographs oI top coat/bond coat/substrate
systems with bond coat thickness oI d 280 m prepared using the (a) HVOE
and (b) APS processes. Indentation was carried out using a WC sphere with
r 3.18 mm, P1000 N, and Irequency 10 Hz Ior n10
5
.
3489 J.-Y. Kwon et al. / Surface & Coatings Technologv 201 (2006) 34833490
interIace samples show an accumulation oI damage and the
evolution oI Iracture in the TBC system. These indicate that the
bond coat nature and its thickness aIIect the contact damage
obtained Irom cyclic contact tests, including the eIIect oI the top
coat on the evolution oI damage.
--
The mechanical properties, E and H, oI the bond coat are
dependent on the preparation process, and show higher values
when the bond coat is Iabricated using the HVOE process. The
values oI E and H in the TBC system with the HVOE bond coat
show a step-like decrease Irom the substrate and the top coat,
whereas the values oI the APS bond coat show a sudden
decrease on passing through the interIace between the substrate
and the bond coat. The values oI E and H are strongly
inIluenced by the bond coat nature. In the TBC system with the
HVOE bond coat, the stressstrain curves are not much aIIected
by the bond coat thickness, except in the lower and higher stress
regions oI the bond coat/substrate and the top coat/bond coat/
substrate systems, respectively. Consequently, the top coat and
the bond coat result in a soItening oI the substrate, with a
resulting lower eIIect oI the bond coat. The stressstrain curves
Ior the APS bond coat are much lower that those oI the HVOE
process, especially Ior the thick bond coat. However, the
relatively hard bond coat Iormed using the HVOE process
diminishes the eIIect oI soItening and the thickness, which is
consistent with the observed mechanical properties.
The subsurIace damage indicates that the thick bond coat is
more eIIicient Ior protecting the substrate Irom the contact
environment than the thin bond coat. The TBCsystemwithout the
top coat, i.e., bond coat/substrate system, also exhibits well-
deIined damage within the bond coat, with a minor damage in the
substrate, and this represents a larger contact diameter Ior the APS
process, but independent oI the number oI cycles. The damage
Iormed in the thick bond coat is not extended and the bond coat/
substrate only shows damage that has accumulated within the
bond coat at a relatively low load oI P500 N, whereas the
damage zone in the thin bond coat is well deIined in the substrate
and extended into the substrate with increasing the number oI
cycles. The HVOE bond coat is eIIicient in improving the damage
tolerance oI the TBC system. The Iracture oI the top coat in the
TBCsystemwith the HVOE bond coat is due to compression with
less crack coalescence, whereas the Iracture with the APS bond
coat is due to the mixed mode oI compression on the top coat and
bending in the bond coat with the Iormation oI larger open cracks.
The damage mode in the bond coat and the substrate oI the TBC
system with the HOVE bond coat Iollows the mechanical
properties oI each coat and shows a gradual transition Iromthe top
coat to the substrate. The bond coat should act as a protective layer
Ior impacts. However, the TBC system with the APS bond coat,
which has similar mechanical properties to the top coat, enhances
damage in the substrate and shows a bigger damage in the bond
coat.
-
This work was Iinancially supported by MOCIE through an
EIRC program, a program Ior cultivating graduate students in
regional strategic industry, and Changwon National University
in 2005. Thanks are due to Brian Lawn Ior providing continual
encouragement during this work.
-
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