In this work, finite element analysis is used to investigate the effect of pore size on the stress intensity factor (SIF) of plasma sprayed coatings. Test samples with different pore sizes were obtained by spraying wollastonite powders with particle sizes of 60-75 μm, 75-95 μm, and 95-150 μm onto Ti6Al4V coupons. The results show that coating stress varies in proportion to the length of 2D pores and to a lesser extent the diameter of 3D pores. This implies that reducing the length of 2D pores may be considered as a way to increase the fracture resistance of plasma sprayed coatings.

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