Experimental and computational study on sintering of ceramic coating layers with complex porous structures

This study investigated the sintering behavior of an yttria‐stabilized zirconia coating for thermal barrier coatings (TBCs) with a complicated porous structure via both experiment and simulation using the finite element method for samples with only a coating (free coating) and samples with coating on a substrate (constrained coating). Sintering and grain growth proceeded from the bottom of the coating, and the coating bent convex upward in the free coating. In the constrained coating, sintering and grain growth proceeded in a manner similar to the free coating; however, the degrees of sintering and grain growth were small. Furthermore, sintering and grain growth were delayed because of substrate constraints. As a simulation result, the free coating was bent in a manner similar to the experiment. The experimental results could be reproduced in terms of time dependency and temperature dependency. The decrease in the porosity of the constrained coating was delayed compared with that in the free coating because of substrate constraints. This simulation result was able to reproduce the experimental results. Thus, the sintering behavior for the complex porous structures of TBCs can be predicted by experimental research and simulation, which could aid in the development of a prediction technology for the delamination of coatings (TBC lifetime). This study investigated the sintering behavior of a coating with complex porous structures via both experiment and simulation. The simulation results for samples with only a coating indicated that the model bent as observed in the experiment, and the experimental results could be reproduced in terms of the time dependency and temperature dependency of bending.