Ceramic Coating Edge Failure Due to Thermal Expansion Interference

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Abstract
An investigation of thermal barrier coatings on a metal substrate was conducted when the assembly was subjected to both thermal heating and mechanical edge loads generated by interference in adjoining expansion gaps. Both finite element and closed form solution models were developed and compared. The results of the analyses predict that the application of both thermal and mechanical edge loads on the edge of ceramic/metal composites can produce severe local edge spallation in the ceramic coating when an inadequate expansion gap is provided.