Design of an Environmental Barrier Coating Bond Strength Test Coupon

The bond strength of an environmental barrier coating (EBC) to a substrate such as a silicon carbide fiber/silicon carbide matrix (SiC/SiC) ceramic matrix composite (CMC) is a function of coating application parameters, matrix surface roughness, and environmental exposure, which results in the formation of a thermally grown oxide layer (TGO) layer. Current estimates of the EBC bond strength to a substrate are made assuming that the applied force divided by pull tab area is a representative metric. Although this is an expedient method for rapid strength estimates, the process of bonding the EBC to a pull-tab creates thermo-elastic residual stresses that are superimposed with the applied tensile load. Minimization of these stresses via test specimen design should give the most realistic estimate of EBC bond strength. We examine the residual stresses imposed on the EBC by cooling of an adhesive layer bonded to various metal and ceramic tabs. The results are extended to examine the stress distribution in a TGO layer formed on a Plasma Spray-Physical Vapor Deposited (PS-PVD) Yb₂Si₂O₇ (ytterbium disilicate) EBC. An EBC/substrate coupon that overhangs a titanium or Kovar^® pull tab is recommended in order to minimize thermal stresses, avoid edge effects, and provide an acreage strength measurement. The test method is sensitive to changes in substrate surface finish and oxidation time.