Surface patterning of the bond coat using a three-dimensional mesh offers a promising approach to improve the durability of the thermal barrier coatings (TBCs), in which the geometry parameters of the mesh play a vital role. The objective of this work is to investigate the failure behavior of the air-plasma sprayed TBCs with mesh, and to identify the optimal mesh design. The study revealed that the failure sequence of the TBCs with mesh patterns consisted of (I) initiation of the interfacial and ridge cracks (around the top of the mesh); (II) cracks propagation and buckling of the YSZ layer; (III) interfacial cracks deflection and coalescence with ridge cracks, leading to final * Corresponding author: Xiaofeng Zhao Tel./fax: +86-21-54742561. xiaofengzhao@sjtu.edu.cn 2 spallation. The critical parameters governing each step of the failure sequence were discussed and proposed. For a typical TBCs with YSZ thickness about 200 μm, the critical mesh height h and spacing length L is about 110 μm and 7 mm respectively when the mesh width w is fixed at about 480 μm.

中文翻译：

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界面由 3D 网格图案修改的热障涂层：失效分析和设计优化

使用三维网格对粘合涂层的表面图案化提供了一种有前途的方法来提高热障涂层 (TBC) 的耐久性，其中网格的几何参数起着至关重要的作用。这项工作的目的是研究带有网格的空气等离子喷涂 TBC 的失效行为，并确定最佳网格设计。研究表明，具有网格图案的 TBC 的失效序列包括 (I) 界面裂纹和脊裂纹（围绕网格顶部）的萌生；(II) YSZ层的裂纹扩展和屈曲；（三）界面裂纹偏转并与脊裂纹合并，导致最终* 通讯作者：赵晓峰 电话/传真：+86-21-54742561。xiaofengzhao@sjtu.edu.cn 2 散裂。讨论并提出了控制故障序列每个步骤的关键参数。对于典型的 YSZ 厚度约为 200 μm 的 TBC，当网格宽度 w 固定在约 480 μm 时，临界网格高度 h 和间距长度 L 分别约为 110 μm 和 7 mm。