Modeling of Coating Process, Phase Changes, and Damage of Plasma Sprayed Thermal Barrier Coatings on Ni‐Base Superalloys

Abstract The paper gives an overview on the modeling activities on plasma sprayed thermal barrier coating in the frame of TFB 63. In the first part, through‐process modeling of the APS deposition of a ZrO₂ based TBC is described. Starting from simulation of the plasma jet, heat transfer into the powder particles, particle melting, particle impact on the substrate surface, and solidification is simulated. A homogenization method is introduced to describe the mechanical properties of the resulting TBC. The second part shows simulation of interdiffusion and phase transformations of MCrAlY and intermetallic oxidation protection coatings on several cast Ni‐base alloy substrates. Finally, FEM‐based damage simulation of oxidation protection coatings by transversal fatigue cracks during thermomechanical fatigue loading as well as by delamination of the TBC during thermocyclic loading is discussed.