Research on strain distribution and damage behavior of thermal barrier coatings based on digital image correlation

Due to the complicated structure and serving environments, thermal barrier coatings (TBCs) usually encounter failure in the form of surface coating cracking and interface spalling without warning. At present, although many experimental techniques and equipment were developed to predict their service life, the transfer process of stress between different layers and the strain characteristics of ceramic surface are not clearly explained. In this paper, the nondestructive digital image correlation method was used to observe the character of surface strains of supersonic plasma-sprayed TBCs systems in tensile failure processes. Also, mathematical model was established basing on the principle of minimum function to calculate interface stress and coating strain expressions. The results show the characteristics of strain change in the whole tensile stage can be divided into four stages. At first, strain concentration occurs in the range of 9%-27% of the effective distance between one end of the tensile specimen, second, a certain number of strain fringes are formed and distributed at a certain distance, and then the first crack appears in the initial strain concentration area; as the load continues, more and more cracks on the coating surface reach saturation and finally fail. In the microlinear elasticity stage, the shear strain in the coating and the interface shear stress are in a linear relationship. As the thickness of the single-layer coating increasing, the strain value of the surface strain of the coating decreases, the surface strain value of the single-layer coating is about six times larger than that of the double-layer coating.