Residual stress distributions within high-temperature coatings

The residual stress distributions of ZrO2/NiCoCrAlY high-temperature coatings were analyzed using an analytical model and finite element analysis. Three different topics were involved, namely the effect of interlayer on the stress distribution, the zero-deflection design for typical duplex-layer thermal barrier coating-based system, and the edge effect on the residual stress distribution. These topics could provide some insights into the development of a fail-safe design methodology for high-temperature coating systems.