High temperature thermal fatigue causes the failure of Thermal Barrier Coating (TBC) systems. This paper addresses the development of thick TBCs, focusing attention on the microstructure and the porosity of the Yttria Partially Stabilized Zirconia (YPSZ) coating, in relation to its resistance to thermal cycling fatigue. Thick TBCs, with different grade of porosity, were produced by means of a CoNiCrAlY bond coat and Yttria Partially Stabilised Zirconia top coat, both sprayed by Air Plasma Spray. The thermal fatigue resistance of new TBC systems and the evolution of the coatings before and after thermal cycling were evaluated. The limit of thermal fatigue resistance increases with amount of porosity in the top coat. Raman analysis shows that the compressive in-plane stress increases in the TBC systems after thermal cycling, nevertheless the increasing rate has a trend contrary to the porosity level of top coat.

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