A numerical simulation of a cylindrical system with plasma sprayed thermal barrier coatings under typical thermal loading was conducted

and the failure mechanisms were analyzed based on the stresses in ceramic coat. It is found that

there are two types of interfacial (transverse) cracking patterns of the ceramic coat:in the cooling process

mode Ⅰ is vulnerable to crack at the peak position of the cosine curve

and mode Ⅱ at the middle position; in the heating process

interface edges are introduced into the ceramic coat/substrate system as a result of the vertical cracks emergence

and the ceramic coat will transversely crack at these positions because of the stress concentration effect.