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Thick thermal barrier coatings with thicknesses on the order of a few millimeters are being developed for use in diesel engines with operating temperatures of about 800°C. In this environment, a coating will experience thermomechanical cycling due to differences in elastic and thermal expansion properties between the coating and the substrate. The inelastic constitutive behavior of the coating material results in both compressive and tensile stresses. To observe the effects of such stresses, specimens of plasma-sprayed 8%Y2O3-ZrO2 were fabricated to allow testing of the coating material independent of the substrate. Cyclic compression fatigue tests were conducted at room and high temperature (SOOT) to simulate the loading environment to which the coating materials will be exposed during service. At high temperature, the compressive fatigue strength of the coating material increased by nearly 100%. Fatigue tests in tension and combined tension/compression were conducted at room temperature to evaluate the effect of mean stress. It was observed that a varying mean stress had no significant impact on the fatigue lives of the coating material and the fatigue life was controlled by the maximum tensile stress of the cycle. Results from fatigue tests and SEM observations indicated that the damage accumulated during the tensile and the compressive portions of the fatigue cycle were independent of each other.

Thick thermal barrier coatings (TTBCs) for diesel engine applications are being developed to improve engine performance through increased operating temperatures and lower emissions. To more completely assess the bulk properties of coating materials, a miniature test stand for the mechanical testing of coating materials independent of the substrate was developed. Using a piezoelectric translator as an actuator and a miniature load cell, it was possible to conduct uniaxial testing in both compression and tension of very small samples. In this study, room temperature deformation experiments were conducted on an air plasma-sprayed 24% CeO2-ZrO2 coating material. Mechanical properties in both the in-plane and transverse coating directions were evaluated in both compression and tension. From simple monotonic tests, the anisotropy of the material could be quantified. A key finding was that both the loading modulus and tensile strength were about two to three times higher in the in-plane direction. This anisotropy is believed to be due to the directionality of microcracking in the material. Cyclic loading experiments showed that the coating material also exhibits considerable irreversible strain behavior in both the transverse and in-plane directions. A model describing the irreversible strain behavior based on the combined sliding and closing of pre-existing microcracks is proposed and compared with experimental results. It is shown that the model describes the qualitative and quantitative aspects of the material behavior quite well, especially in compression.