AN INVESTIGATION INTO THE EFFECT OF CRITICAL PARAMETERS ON RESIDUAL STRESS BUILD-UP IN THERMAL BARRIER COATING

Year 2015, Volume: 7 Issue: 1, 44 - 58, 01.03.2015

B. Srivathsa D.K. Das

https://doi.org/10.24107/ijeas.251245

Abstract

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 TBC on a coupon during thermal cycling has been studied by varying three
parameters such as cooling rate, TBC thickness and substrate thickness. A two-dimensional thermo-mechanical
plane strain finite element simulations have been performed for thousand cycles. It was observed that these
variations change the stress profile significantly and stress severity factor increases non-linearly. Overall, the
predictions of the model agree with reported experimental as well as simulated results.

Keywords

Thermal barrier coatings, residual stress, Modeling and simulation

References

• [1]. R. A. Miller, Thermal barrier coatings for aircraft engines: history and directions, J. Therm. Spray Technology, 6, 35-42,1997.
• [2]. S.M. Meier, D.K. Gupta, The Evolution of Thermal Barrier Coatings in Gas Turbine Engine Applications, Trans. ASME, 116, 250-256, 1994.
• [3]. D.R. Clarke and C.G. Levi, Materials design for the next generation thermal barrier coatings, Annu. Rev. Mater.Res, 33,383-417, 2003.
• [4]. C.A. Johnson, J.A. Ruud, and R Bruce, Relationships between residual stress, Microstructure and mechanical Properties of electron beam–physical vapor deposition thermal barrier coatings, Surface and Coatings Technology, 108, 80–85, 1998. [5]. D. Schwingel, R. Taylor, T. Haubold, J. Wigren, and C. Gualco, Mechanical and Thermo-physical properties of thick YSZ, Thermal Barrier Coatings: Correlation with Microstructure and Spraying Parameters, Surf, Coat, Technol., 108, 99-106,1998.
• [6]. S. Alperine, L. Lelait, Microstructural investigations of plasma-sprayed yttria partially stabilizes zirconia TBC, Transactions ASME: Journal of Engineering for Gas Turbines and Flows, 116, 258–265,1994.
• [7]. P.Y. Pekshev, I.G. Murzin, Modeling of Porosity of Thermal Barrier Coatings, Surf. Coat. Tech., 56, 199-208, 1993.
• [8]. P. Scardi, M. Leoni, L. Bertamini, and M. Marchese, Residual stress in coatings on piston heads, Surf. Coat. Tech., 86,109-115, 1996.
• [9]. R.T. McGrann, D.J. Greving, J.R. Shadley, E.F. Rybicki, T.L. Kruecke T.L, and B.E. Bodger, The effect of coating residual stress on the fatigue life of thermal spray-coated steel and aluminum, Surf. Coat. Tech., 108, 59-64, 1998.
• [10]. G. Qian, T. Nakamura, and C.C Berndt, Effects of thermal gradient and residual stresses on thermal barrier coating, Mechanics of Materials 27, 91–110, 1998.
• [11]. A G Evans, D RMumm, J Hutchinson, G H Meier and F S Zettit, Mechanism controlling the durability of thermal barrier coatings, Progress in Materials Sci.,46, 505-553, 2001.
• [12]. P K Wright, A G Evans, Mechanisms governing the performance of TBCs, Current opinions in Solid State and Mater Sci, 4, 255–265, 1999.
• [13]. C H Hsueh and E R Fuller, Analytical modeling of oxide thickness effects on residual stresses in thermal barrier coatings, Scripta Materialia, 42,781–787,2000.
• [14]. Chun-Hway, Hsnech and Edwin R Fuller Jr, Residual stresses in thermal barrier coatings: effects of interface asperity curvature/height and oxide thickness, Material Science and Engineering A, 283, 46–55, 2000.
• [15]. B Srivathsa, Zafir Alam Md, S V Kamat and D K Das, Modelling of Residual stresses developed in thermal barrier coatigs during thermal cycling, Int. Jl. App. Mechanics and Engg.,16, 3, 869-883, 2011
• [16]. Piotr Bednarz, Finite Element Simulation of stress evolution in Thermal Barrier Coating systems, Ph.D thesis, Forschungszentrum Jülich, 2007.
• [17]. W G Mao and Y C Zhou, Failure of Thermal Barrier Ceramic Coating induced by buckling due to temperature gradient and creep, Advanced Mat. Res. 9, 31-40,2005.
• [18]. Chen Xiao, Zhang Yue and Gong Sheng, Finite element analysis of stresses and interface crack in TBC system, Trans. Non-Ferrous Met. Soc. China, 15,2, 457- 460,2005.
• [19]. J D Lee, H Y Ra, K T Hong, and S K Hur, Analysis of Deposition Phenomena and Residual Stress in Plasma Spray Coatings, Surf. Coat. Tech., 56,1, 27-37,1992.
• [20]. D Pan, M W Chen, P K Wright and K J Hemker, Evolution of a diffusion aluminide bond coat for thermal barier coatings during thermal cycling, Acta Mat, 51,2205- 2217,2003.
• [21]. M Bialas, Finite Element Analysis of stress distribution in thermal barrier coatings, Jl. of Surf. Coat. Tech., 202, 6002-6010,2008.
• [22]. E Shillington and D R Clarke, Spalling failure of a thermal barrier coating associated with aluminium depletion in the bond coat, Acta Mat, 47,1297-1305,1999.
• [23]. A G Evans, J W Hutchinson and Y Wei, Interface adhesion: effects of plasticity and segregation, Acta Mater., 47 15, 4093,1999.
• [24]. A M Karlsson, C G Levi and A G Evans, A model study of displacement instabilities during cyclic oxidation, Acta Materilia, 50,1263–1273,2000.
• [25]. A M Karlsson, T XU and A G Evans, The effect of the thermal barrier coating on the displacement instability in thermal barrier systems. Acta Materilia, 50,1211– 1218,2000.
• [26]. Sujanto Widjaja, Andi Limarga and Tick Hon Yip, Modelling of residual stresses in a thermally graded thermal barrier coating, Thin solid films, 434, 216-227,20003.
• [27]. M A Helminiak, Factors effecting the lifetime of thermal barrier coatings, Mech. of Mat. 26,91-110,1998.
• [28]. S Stephan, Advanced thermal barrier system coatings for use on Ni-,co-, and Febased substrates, Lewis Research Center: No.NASA-TM-87062, Cleveland, Ohio,1985.
• [29]. A M Karlson and A G Evans, A numerical model for the cyclic instability of thermally grown oxides in thermal barrier systems. Acta mater, 49,1793–1804,2001.
• [30]. V Teixeira, M Andritschky and W Fischer, Analysis of residual stresses in thermal barrier coatings, Jl. of Mat. Pro. Technology, 92,209-216,1999.
• [31]. Zhang Yue, Zhang yarji, Jinghua Gu, A computational simulation of interaction between polyelectrolyte and ceramic particles, Key Engg. Materials, 224, 697- 701,2001.
• [32]. D M Zhu and A M Robert, Determination of creep behaviour of thermal barrier coatings under laser imposed high thermal and stress gradient conditions, J. mater. Res. 14, 146-161,1999.
• [33]. J W Hutchinson, Delamination of compressed multilayers on curved Substrates, J.Mech. Phys. Solids, 49, 1847–1864,2001.
• [34]. S Faulhaber, C Mercer, M W Moon, J W Hutchinsonand A G Evans, Buckling delamination in compressed multilayers on curved substrates with accompanying ridge cracks, J. Mech. Phys. Solids, 54, 1004–1028,2006.
• [35]. A M Karlsson, T XU and A G Evans, The effect of the thermal barrier coating on the displacement instability in thermal barrier systems. Acta Materilia, 50,1211– 1218,2002.
• [36]. W G Mao, J P Jiang, Y C Zhou and C Lu, Effects of substrate curvature and radius, deposition temperature and coating thickness on the residual stress field of cylindrical thermal barrier coatings, Surface & Coatings Technology, 8-9, 205-211,2011.
• [37]. A M Karlsson, C G Levi and A G Evans, A model study of displacement instabilities during cyclic oxidation, Acta Materilia, 50, 1263–1273,2002
• [38]. A M Limarga, Widjaja, Sujanto, Yip, Tick Hon, Teh, Lay Kuan, Modeling of the effect of Al2O3 interlayer on residual stress due to oxide scale in thermal barrier coatings, Surface and Coatings Technology, 153(1), 16-24,2002.
• [39]. M Y He, A G Evans and J W Hutchinson, The ratcheting of compressed thermally grown oxide on ductile substrate, Acta Mat. 48, 2593-2601,2000.