The surface fracture toughness is an important mechanical parameter for studying the failure behavior of air plasma sprayed (APS) thermal barrier coatings (TBCs). As APS TBCs are typical multilayer porous ceramic materials, the direct applications of the traditional single edge notched beam (SENB) method that ignores those typical structural characters may cause errors. To measure the surface fracture toughness more accurately, the effects of multilayer and porous characters on the fracture toughness of APS TBCs should be considered. In this paper, a modified single edge V-notched beam (MSEVNB) method with typical structural characters is developed. According to the finite element analysis (FEA), the geometry factor of the multilayer structure is recalculated. Owing to the narrower V-notches, a more accurate critical fracture stress is obtained. Based on the Griffith energy balance, the reduction of the crack surface caused by micro-defects is corrected. The MSEVNB method can measure the surface fracture toughness more accurately than the SENB method.

Premature failure of thermal barrier coatings (TBCs) under a temperature gradient is an overriding concern in many applications, and their mechanical parameters are essential to failure analysis. In this study, an in situ micro-indentation apparatus, including a heating module, cooling module, and micro-indentation module, was developed to study the mechanical parameters of TBCs with a temperature gradient. The upper surface of the TBC was heated by radiation to simulate high-temperature service conditions, and the bottom surface was gas-cooled. Different temperature gradients are obtained by changing the velocity of the cooling gas. The temperatures through the thickness of the TBCs were analyzed by numerical simulations and experiments. During exposure to the temperature gradient, micro-indentation tests of the TBC samples were conducted to obtain their mechanical parameters. In situ micro-indentation tests at different cooling gas flow rates (0, 20, and 40 l/min) were performed on the TBCs. The elastic modulus and stress evolution of the TBCs were extracted by analyzing the load–displacement curves at different gas velocities. The elastic modulus remains almost constant with increasing velocity while the stress difference increases.