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The role of bond coat (BC)–thermal barrier coating (TBC) interfacial morphology on the failure of yttria-stabilized zirconia (YSZ) air plasma sprayed (APS) thermal barrier coatings on a NiCoCrAlY bond coat has been investigated. Interfacial morphology plays a key role in the generation of compressive and tensile stresses normal to the global surface plane through oxide growth processes and microstructural...