TBCs were failed via piece-by-piece spallation of topcoat in thermal shock codnition but via peeling of the whole topcoat layer in thermal-ageing failure condition. Increasing the MCrAlY interface roughness improves the TBCs life in both test conditions. Increased MCrAlY roughness transfers fracture of TBCs from ceramic top coat to the MCrAlY interface in thermal shock. Higher MCrAlY roughness promotes larger deformation zone in the MCrAlY which may help to release some stresses in the topcoat.
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