Effects of compositional gradient and thickness of coating on the residual stresses within the graded coating

The effects of compositional gradient and thickness of coating on the residual stresses within the ZrO2/NiCoCrAlY graded coating were analysed using finite element method. The compositional gradient was characterized by the gradient component. Modeling results showed that the presence of graded properties and compositions within the coating did reduce the stresses discontinuities at the interfaces in the coating. The compositional gradient of coating had an obvious influence on the residual stress magnitude at the coating/substrate interface and the location of stress concentration near the edge of the coating. Also, the magnitudes of residual stresses on the coating surface and at the coating/substrate interface were dependent on the coating thickness.