The role of the surface morphology and segmented cracks on the damage forms of laser re-melted thermal barrier coatings in presence of a molten salt (Na₂SO₄ + V₂O₅)

Hot corrosion behaviour of yttria-stabilized zirconia thermal barrier coatings (TBCs) with various segmented cracks and surface morphologies, obtained using ultrasonic-assisted laser re-melting, was investigated during exposure to Na₂SO₄ + V₂O₅salt at 1100 °C. It is demonstrated, that the damage types of TBCs were significantly affected by segmented cracks and surface morphology. Four main damage mechanisms: (i) chemical reaction, (ii) Coefficient thermal mismatch stress, (iii) oxidation of bond coating and (iv) intergranular corrosion, based on the observed transport behaviour of oxygen and molten salt, stress-tolerance and self-healing of various segmented cracks, were discussed to account for the failure behaviour.