A finite element model of electron beam-physical vapor deposition (EB-PVD) thermal barrier coating (TBC) considering crystalline columns was developed

the influence of CMAS deposition and penetration on residual stresses was systematically studied. The results showed that large in-plane and out-of-plane residual tensile stresses were induced by CMAS deposition and penetration

the vertical and horizontal cracks were easily initiated and propagated

finally TBC failed due to the spall off and delamination. These failure modes mainly happened at three regions: closely beneath the surface of TC

the interface between CMAS penetration and none penetration zone

and close to the top coating/bond coating(TC/BC) interface.