This work assesses the effects of defects in thermally sprayed chromia via multiscale modeling and imaging techniques. Defect distributions in coating samples are identified by way of image processing and synthetic 3D microstructures are generated from extracted statistical information. The properties of the microstructures are determined by subjecting them to simulated tensile testing, and the significance of different types of defects is evaluated through defect-containing coating models. The approach is able to handle complex defect morphologies, including pore, crack, and splat boundary clusters, making it a versatile tool for assessing the influence of defects on component performance.

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