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In this work, the interdiffusion between a MCrAlY‐bond coat and two different nickel‐based superalloys is evaluated at three temperatures, 950 °C, 980 °C, and 1,050 °C. Of primary interest is the evolution of Kirkendall‐porosity, the β‐depleted zone in the bond coat and the β’‐ depleted zone in the superalloy. The three phenomena arise near the interface between bond coat and superalloy as a result of interdiffusion between both materials and are detrimental to the coating‐substrate system. The evolution of the interdiffusion phenomena is highly dependent on the alloy composition of the materials as well as the annealing temperature. It has been found that not only the temperature dependency of the diffusion coefficient but also the temperature dependent element activities are an important factor when evaluating the interdiffusion phenomena. It has further been shown that at lower temperatures the amount of Kirkendall‐porosity per volume fraction is higher than at higher temperatures, even though the overall amount of porosity is lower. Different equilibrium concentrations of main alloying elements and a correspondingly lower over‐saturation of vacancies have been identified as the main explanation.

A Vickers indentation method has been applied to determine the interfacial fracture toughness of modern multilayer thermal barrier coatings. The delamination behavior of four types of coating systems will be discussed and compared with results based on modified four-point bending (4PB) tests. The investigated multi-layer coating system consists of a CoNiCrAlY-bond coat applied via low-pressure plasma spray (LPPS) on a nickel-based superalloy and an atmospheric-plasma sprayed (APS) top layer of type gadolinium zirconate (GZO) and yttria-stabilized zirconia (YSZ). A conventional YSZ mono-layer system is used for reference. The effects of GZO and YSZ microstructure were investigated using top coats with low and high porosities for both (multi- and single-layer) coating systems. Isothermal oxidation tests at 1100 °C up to 500 hours were performed to study the interaction between thermal aging and fracture behavior. Investigations of microstructure and sintering behavior show a significant influence of the annealing conditions on fracture toughness. It has been observed, that with increasing annealing time, the stiffness and thus the crack driving force of the GZO layer is increased due to sintering effects and healing of submicron defects. The lower stiffness and higher defect density of GZO seem to be the main reason for the reduced fracture toughness of the YSZ / GZO interface compared to the YSZ / CoNiCrAlY interface. As a result, the delamination of the top coat is observed to shift from the top coat / bond coat interface into the top coat double-layer.