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This paper describes a through‐process modelling on a microstructural level of the production of a coated turbine blade, including its in‐service properties and degradation, accompanied by the actual production and testing of a CMSX‐4 single crystal turbine blade dummy. The following steps are dealt with by modelling and experiment: solidification of the blade alloy during casting, microstructural changes during homogenization and aging heat treatments, chemical vapour deposition of an Al2O3 diffusion barrier coating, physical vapour deposition (sputtering) of a (Ni,Co)CrAlY bond coat, atmospheric plasma spraying of an Y2O3 stabilized ZrO2 thermal barrier coating and microstructural changes and development of critical stresses at in‐service conditions. This work forms a part of the Collaborative Research Centre 370 (SFB 370) “Integrative materials modelling”.

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.

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