Interfacial Characteristics Investigation for One-Step EDM Drilling of Cooling Holes in TBCs

In this study, the one-step electrical discharge machining of inclined cooling holes is performed in thermal-barrier-coated nickel-based superalloys via the assisting electrode method. The effects of the process parameters, including the inclination angle, peak current, pulse duration, and duty cycle, on interfacial characteristics of cooling holes were investigated. The research results are as follows: After machining, the hardness of TBCs increases slightly and the adhesion strength of ceramic coating has a slight reduction. Delamination prevailingly appears at the ceramic coating/bonding coating interface, and its length at the trailing edge is greater than that at the leading edge. Increasing either the discharge energy or the duty cycle also aggravates the severity of the delamination. Under an excessive peak current of 22.5 A, the complete spalling of the ceramic coating occurs in the vicinity of the holes. Additionally, a reduction in the inclination angle results in a significant increase in delamination cracking and poorer interface integrity. The interfacial microstructure features of the holes vary with the inclination angle. The large-scale spalling of ceramic coating is prone to occur at the trailing edge when using an inclination angle of 30°. The spattering is susceptible to appear at the entrance of the holes under inclination angles of 60° and 75°, and its composition is primarily Ni, C, Zr, Cr, Nb, Fe, and Cu.