An FE model using XFEM implemented in ABAQUS was developed to investigate crack initiation and propagation for various TGO thicknesses considering the effect of plastic deformation of BC, TGO and substrate. Image processing is used to convert an SEM image, including pores, into a finite element (FE) model. This work investigates effect of pores and TGO thickness on crack initiation and propagation due to thermal mismatch between TBC layers. Thermally grown oxide (TGO) causes cracks formation in the top coat (TC) that may lead to spallation failure of TBC. Thermal Barrier Coatings (TBC) are widely used to protect the metallic components that operate at harsh conditions of elevated temperatures and oxidizing environments.
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