| Abstract Scope |
High-temperature components in power generation operate under extreme environments, exceeding the limits of Ni-based superalloys. Thermal barrier coatings (TBCs), applied for their low thermal conductivity, reduce surface temperatures but deteriorate under prolonged exposure, compromising turbine performance and service life. TBCs require reliable property evaluations, particularly spallation life assessments under realistic thermal fatigue conditions. However, thermal fatigue evaluation remains challenging due to high costs, long testing times, and complexity. Therefore, this study proposed a numerical methodology to predict the spallation life of TBCs under different thermal fatigue conditions. As a first step, thermally grown oxide (TGO) growth models were optimized, focusing on long-term exposure, using isothermal aging test results. Thermo-mechanical finite element analysis was also performed to predict thermal stresses as a function of TGO thickness. Finally, the optimized TGO growth model and thermal stress analysis were coupled to build a thermal fatigue life prediction methodology, and its applicability was assessed. |