Abstract
Highly porous zirconia based thermal barrier coatings have recently been synthesised with zig-zag morphology pores which appear to impede heat flow through the thickness of the coating. A combined analytical/numerical study of heat conduction across these microstructures is presented and compared with thermal conductivity measurements. The effects of pore volume fraction, pore type, pore orientation and pore spacing, together with the wave length and the amplitude of zig-zag pore microstructures on overall thermal performance are quantified. The results indicate that even a few volume percent of zig-zag inter-column pores oriented normal to the substrate surface reduce the overall thermal conductivity of the coatings by more than 50%.