Parametric studies of failure mechanisms in thermal barrier coatings during thermal cycling using FEM

• Autorzy: Srivathsa B. , Das D. K.

Identyfikatory

DOI

10.1515/ijame-2015-0058

• Języki publikacji: EN

Abstrakty

EN

Thermal barrier coatings (TBCs) are widely used on different hot components of gas turbine engines such as blades and vanes. Although, several mechanisms for the failure of the TBCs have been suggested, it is largely accepted that the durability of these coatings is primarily determined by the residual stresses that are developed during the thermal cycling. In the present study, the residual stress build-up in an electron beam physical vapour deposition (EB-PVD) based TBCs on a coupon during thermal cycling has been studied by varying three parameters such as the cooling rate, TBC thickness and substrate thickness. A two-dimensional thermomechanical generalized plane strain finite element simulations have been performed for thousand cycles. It was observed that these variations change the stress profile significantly and the stress severity factor increases non-linearly. Overall, the predictions of the model agree with reported experimental results and help in predicting the failure mechanisms.

Słowa kluczowe

EN

thermal barrier coatings; residual stress; failure mechanisms; modeling and simulation

PL

naprężenia szczątkowe; mechanizm uszkodzenia; modelowanie; symulacja

• Wydawca: Oficyna Wydawnicza Uniwersytetu Zielonogórskiego
• Czasopismo: International Journal of Applied Mechanics and Engineering
• Rocznik: 2015
• Tom: Vol. 20, no. 4
• Strony: 899--915
• Opis fizyczny: Bibliogr. 37 poz., rys., tab., wykr.

Twórcy

autor

Srivathsa B.

• Defence Metallurgical Research Laboratory Kanchanbagh, Hyderabad 500 058, INDIA

autor

Das D. K.

• Defence Metallurgical Research Laboratory Kanchanbagh, Hyderabad 500 058, INDIA

Bibliografia

• [1] Alperine S. and Lelait L. (1994): Microstructural investigations of plasma-sprayed yttria partially stabilizes zirconia TBC. – Transactions ASME - Journal of Engineering for Gas Turbines and Flows, vol.116, pp.258–265.
• [2] Bednarz P. (2007): Finite Element Simulation of Stress Evolution in Thermal Barrier Coating Systems. – Ph. D Thesis, Forschungszentrum Jülich.
• [3] Bialas M. (2008): Finite element analysis of stress distribution in thermal barrier coatings. – Jl. of Surf. Coat. Tech., vol.202, pp.6002-6010.
• [4] Chen Xiao, Zhang Yue and Gong Sheng (2005): Finite element analysis of stresses and interface crack in TBC system. – Trans. Non-Ferrous Met. Soc. China, vol.15, No.2, pp.457-460.
• [5] Chun-Hway, Hsnech and Edwin R. Fuller Jr (2000): Residual stresses in thermal barrier coatings: effects of interface asperity curvature/height and oxide thickness – Material Science and Engineering A, vol.283, pp.46–55.
• [6] Clarke D.R. and Levi C.G. (2003): Materials design for the next generation thermal barrier coatings. – Annu. Rev. Mater. Res, vol.33, pp.383-417.
• [7] Evans A.G., Mumm D.R., Hutchinson J., Meier G.H. and Zettit F.S. (2001): Mechanism controlling the durability of thermal barrier coatings. – Progress in Materials Sci., vol.46, pp.505-553.
• [8] Evans A.G., Hutchinson J.W. and Wei Y. (1999): Interface adhesion: effects of plasticity and segregation. – Acta Mater., vol.47, No.15, pp.4093.
• [9] Faulhaber S., Mercer C., Moon M.W., Hutchinson J.W. and Evans A.G. (2006): Buckling delamination in compressed multilayers on curved substrates with accompanying ridge cracks. – J. Mech. Phys. Solids, vol.54, pp.1004–1028.
• [10] He M.Y., Evans A.G. and Hutchinson J.W. (2000): The ratcheting of compressed thermally grown oxide on ductile substrate. – Acta Mat., vol.48, pp.2593-2601.
• [11] Helminiak M.A. (1998): Factors effecting the lifetime of thermal barrier coatings. – Mech. of Mat., vol.26, pp.91-110.
• [12] Hsueh C.H. and Fuller E.R. (2000): Analytical modeling of oxide thickness effects on residual stresses in thermal barrier coatings. – Scripta Materialia, vol.42, pp.781–787.
• [13] Hutchinson J.W. (2001): Delamination of compressed multilayers on curved Substrates. – J. Mech. Phys. Solids, vol.49, pp.1847–1864.
• [14] Johnson C.A., Ruud J.A. and Bruce R. (1998): Relationships between residual stress, microstructure and mechanical Properties of electron beam–physical vapor deposition thermal barrier coatings. – Surface and Coatings Technology, vol.108, pp.80–85.
• [15] Karlsson A.M., Levi C.G. and Evans A.G. (2002): A model study of displacement instabilities during cyclic oxidation. – Acta Materilia, vol.50, pp.1263–1273.
• [16] Karlsson A.M., XU T. and Evans A.G. (2002): The effect of the thermal barrier coating on the displacement instability in thermal barrier systems. – Acta Materilia, vol.50, pp.1211–1218.
• [17] Karlson A.M. and Evans A.G. (2001): A numerical model for the cyclic instability of thermally grown oxides in thermal barrier systems. – Acta Mater., vol.49, pp.1793–1804.
• [18] Lee J.D., Ra H.Y., Hong K.T. and Hur S.K. (1992): Analysis of deposition phenomena and residual stress in plasma spray coatings. – Surf. Coat. Tech., vol.56, No.1, pp.27-37.
• [19] Limarga A.M., Widjaja, Sujanto, Yip, Tick Hon, Teh, Lay Kuan (2002): Modeling of the effect of Al2O3 interlayer on residual stress due to oxide scale in thermal barrier coatings. – Surface and Coatings Technology, vol.153, No.1, pp.16-24.
• [20] Mao W.G., Jiang J.P., Zhou Y.C. and Lu C. (2011): Effects of substrate curvature and radius, deposition temperature and coating thickness on the residual stress field of cylindrical thermal barrier coatings. – Surface and Coatings Technology, vol.8-9, pp.205-211.
• [21] Mao W.G. and Y. Zhou Y.C. (2005): Failure of thermal barrier ceramic coating induced by buckling due to temperature gradient and creep. – Advanced Mat. Res., vol.9, pp.31-40.
• [22] McGrann R.T., Greving D.J., Shadley J.R., Rybicki E.F., Kruecke T.L. and Bodger B.E. (1998): The effect of coating residual stress on the fatigue life of thermal spray-coated steel and aluminum. – Surf. Coat. Tech., vol.108, pp.59-64.
• [23] Meier S.M. and Gupta D.K. (1994): The evolution of thermal barrier coatings in gas turbine engine applications. – Trans. ASME, vol.116, pp.250-256.
• [24] Miller R.A. (1997): Thermal barrier coatings for aircraft engines: history and directions. – J. Therm. Spray Technology, vol.6, pp.35-42.
• [25] Pan D., Chen M.W., Wright P.K. and Hemker K.J. (2003): Evolution of a diffusion aluminide bond coat for thermal barier coatings during thermal cycling. – Acta Mat., vol.51, pp.2205-2217.
• [26] Pekshev P.Y. and Murzin I.G. (1993): Modeling of porosity of thermal barrier coatings. – Surf. Coat. Tech., vol.56, pp.199-208.
• [27] Qian G., Nakamura T. and Berndt C.C. (1998): Effects of thermal gradient and residual stresses on thermal barrier coating. – Mechanics of Materials, vol.27, pp.91–110.
• [28] Scardi P., Leoni M., Bertamini L. and Marchese M. (1996): Residual stress in coatings on piston heads. – Surf. Coat. Tech., vol.86, pp.109-115.
• [29] Schwingel D., Taylor R., Haubold T., Wigren J. and Gualco C. (1998): Mechanical and thermo-physical properties of thick YSZ, thermal barrier coatings: correlation with microstructure and spraying parameters. – Surf., Coat., Technol., vol.108, pp.99-106.
• [30] Shillington E. and Clarke D.R. (1999): Spalling failure of a thermal barrier coating associated with aluminium depletion in the bond coat. – Acta Mat., vol.47, pp.1297-1305.
• [31] Srivathsa B., Zafir Alam Md, Kamat S.V. and Das D.K. (2011): Modelling of residual stresses developed in thermal barrier coatings during thermal cycling. – Int. J. App. Mechanics and Engg., vol.16, No.3, pp.869-883.
• [32] Stephan S (1985): Advanced thermal barrier system coatings for use on Ni-,co-, and Fe-based substrates. – Lewis Research Center: No.NASA-TM-87062, Cleveland, Ohio.
• [33] Sujanto Widjaja, Andi Limarga and Tick Hon Yip (2003): Modelling of residual stresses in a thermally graded thermal barrier coating. – Thin Solid Films, vol.434, pp.216-227.
• [34] Teixeira V., Andritschky M. and Fischer W. (1992): Analysis of residual stresses in thermal barrier coatings. – J. of Mat. Pro. Technology, vol.92, pp.209-216.
• [35] Wright P.K. and Evans A.G. (1999): Mechanisms governing the performance of TBCs. – Current opinions in Solid State and Mater. Sci., vol.4, pp.255–65.
• [36] Zhang Yue, Zhang Yarji, Jinghua Gu (2001): A computational simulation of interaction between polyelectrolyte and ceramic particles. – Key Engg. Materials, vol.224, pp.697-701.
• [37] Zhu D.M. and Robert A.M. (1999): Determination of creep behaviour of thermal barrier coatings under laser imposed high thermal and stress gradient conditions. – J. Mater. Res., vol.14, pp.146-161.