journal article·2019-09Open access

Three-Dimensional Characterization of Cracks in a Columnar Thermal Barrier Coating System for Gas Turbine Applications

Anne Dennstedt, Fabrice Gaslain, Marion Bartsch, Vincent Guipont, Vincent Maurel

Abstract

Thermal barrier coatings (TBC) are multilayered systems comprising a metallic oxidation protection layer or so-called bond coat, a ceramic topcoat, and a thermally grown aluminum oxide developing at the interface. The coating systems fail typically by delamination cracking near this interface, which has a complex three-dimensional morphology influencing the crack path. This study combines laser shock adhesion test to introduce an artificial interfacial crack, known in size and location, and focused ion beam coupled with scanning electron microscopy 3D serial sectioning tomography. Methods for proper segmentation of cracks and adjacent materials and quantitative evaluation of the complex crack system are proposed and applied for analyzing the crack tip region. Finally, derived from the three-dimensional segmentation, a finite element model has been achieved and used for thermal analysis highlighting the crucial role of local damage on thermal conductivity of the TBC.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: High-Temperature Coating Behaviors · Nuclear Materials and Properties · Particle Dynamics in Fluid Flows

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (31)

Show source-provided references
1. Evans AG, Mumm DR, Hutchinson JW, Meier GH, Pettit FS (2001) Mechanisms controlling the durability of thermal barrier coatings. Prog Mater Sci 46(5):505–55310.1016/S0079-6425(00)00020-7 ↗
2. Nicholls JR, Lawson KJ, Johnstone A, Rickerby DS (2002) Methods to reduce the thermal conductivity of EB-PVD TBCS. Surf Coat Technol 151:383–39110.1016/S0257-8972(01)01651-6 ↗
3. Yanar N, Pettit F, Meier G (2006) Failure characteristics during cyclic oxidation of yttria stabilized zirconia thermal barrier coatings deposited via electron beam physical vapor deposition on platinum aluminide and on nicocraly bond coats with processing modifications for improved performances. Metall Mater Trans A 37(5):1563–158010.1007/s11661-006-0100-4 ↗
4. Bartsch M, Baufeld B, Dalkilic S, Chernova L, Heinzelmann M (2008) Fatigue cracks in a thermal barrier coating system on a superalloy in multiaxial thermomechanical testing. Int J Fatigue 30(2):211–21810.1016/j.ijfatigue.2007.01.037 ↗
5. Hernandez MT, Cojocaru D, Bartsch M, Karlsson Anette M (2011) On the opening of a class of fatigue cracks due to thermo-mechanical fatigue testing of thermal barrier coatings. Comput Mater Sci 50(9):2561–257210.1016/j.commatsci.2011.03.041 ↗
6. Chaudhury ZA, Newaz GM, Nusier SQ, Ahmed T, Thomas RL (1999) Chronological evaluation of interfacial damage in tbc due to thermal cycling. J Mater Sci 34(10):2475–248110.1023/A:1004535305143 ↗
7. Zavattieri PD, Jr Hector LG, Bower AF (2008) Cohesive zone simulations of crack growth along a rough interface between two elastic–plastic solids. Eng Fract Mech 75(15):4309–433210.1016/j.engfracmech.2007.11.007 ↗
8. Bacos MP, Dorvaux JM, Landais S, Lavigne O, Mévrel R, Poulain M, Rio C, Vidal-Sétif MH (2011) 10 years-activities at onera on advanced thermal barrier coatings. AerospaceLab (3):1–14
9. Buffiere J-Y, Maire E, Adrien J, Masse J-P, Boller E (2010) In situ experiments with X-ray tomography: an attractive tool for experimental mechanics. Exp Mech 50(3):289–30510.1007/s11340-010-9333-7 ↗
10. Helfen L, Baumbach T, Pernot P, Mikulík P, DiMichiel M, Baruchel J (2006) High-resolution three-dimensional imaging by synchrotron-radiation computed laminography. Proc SPIE 6318:63180N10.1117/12.680797 ↗
11. Khoshkhou D, Mostafavi M, Reinhard C, Taylor MP, Rickerby DS, Edmonds IM, Evans HE, Marrow TJ, Connolly BJ (2016) Three-dimensional displacement mapping of diffused Pt thermal barrier coatings via synchrotron X-ray computed tomography and digital volume correlation. Scr Mater 115:100–10310.1016/j.scriptamat.2015.10.033 ↗
12. Morgeneyer TF, Besson J (2011) Flat to slant ductile fracture transition: tomography examination and simulations using shear-controlled void nucleation. Scr Mater 65(11):1002–100510.1016/j.scriptamat.2011.09.004 ↗
13. Maurel V, Soulignac R, Helfen L, Morgeneyer TF, Koster A, Remy L (2013) Three-dimensional damage evolution measurement in EB-PVD TBC using synchrotron laminography. Oxid Met 79(3–4, SI):313–32310.1007/s11085-012-9333-3 ↗
14. Duhamel C, Caballero J, Couvant T, Crépin J, Gaslain F, Guerre C, Le H-T, Wehbi M (2017) Intergranular oxidation of nickel-base alloys: potentialities of focused ion beam tomography. Oxid Met 88(3–4):447–45710.1007/s11085-016-9688-y ↗
15. Burns AJ, Subramanian R, Kempshall BW, Sohn YH (2004) Microstructure of as-coated thermal barrier coatings with varying lifetimes. Surf Coat Technol 177:89–9610.1016/j.surfcoat.2003.06.021 ↗
16. Chen X, Shaw C, Gelman L, Grattan KTV (2019) Advances in test and measurement of the interface adhesion and bond strengths in coating-substrate systems, emphasising blister and bulk techniques. Measurement 139:387–40210.1016/j.measurement.2019.03.026 ↗
17. Gupta V, Argon AS, Cornie JA, Parks DM (1990) Measurement of interface strength by laser-pulse-induced spallation. Mater Sci Eng A 126(1–2):105–11710.1016/0921-5093(90)90116-K ↗
18. Guipont V, Begue G, Fabre G, Maurel V (2019) Buckling and interface strength analyses of thermal barrier boatings combining Laser Shock Adhesion Test to thermal cycling. Surf Coat Technol [under revision (special issue 46th ICMCTF)]10.1016/j.surfcoat.2019.124938 ↗
19. Sapardanis H, Maurel V, Köster A, Duvinage S, Borit F, Guipont V (2016) Influence of macroscopic shear loading on the growth of an interfacial crack initiated from a ceramic blister processed by laser shock. Surf Coat Technol 291:430–44310.1016/j.surfcoat.2016.02.050 ↗
20. Theveneau, M, Guipont, V, Marchand, B, Coudon, F, Maurel V (2019) Damage monitoring and thermal cycling life of thermal barrier coating involving LASAT (laser shock adhesion test). Surf Coat Technol [under review (special issue 46th ICMCTF)]
21. Fabre G (2013) Influence des propriétés optiques et de l’endommagement de barrières thermiques EB-PVD pour la mesure d’adhérence par choc laser LASAT-2D. Ph.D. thesis, Mines ParisTech (in French)
22. Linear stack alignment with sift. https://imagej.net/Linear_Stack_Alignment_with_SIFT#cite_ref-1 . Accessed 22 Apr 2019
23. Mumm DR, Evans AG, Spitsberg IT (2001) Characterization of a cyclic displacement instability for a thermally grown oxide in a thermal barrier system. Acta Mater 49(12):2329–234010.1016/S1359-6454(01)00071-4 ↗
24. Karlsson AM, Xu T, Evans AG (2002) The effect of the thermal barrier coating on the displacement instability in thermal barrier systems. Acta Mater 50(5):1211–121810.1016/S1359-6454(01)00422-0 ↗
25. Zotov N, Bartsch M, Eggeler G (2009) Thermal barrier coating systems analysis of nanoindentation curves. Surf Coat Technol 203(14):2064–207210.1016/j.surfcoat.2009.02.008 ↗
26. Avizo for materials science. https://www.thermofisher.com . Accessed 13 Apr 2019
27. Bégué G, Fabre G, Guipont V, Jeandin M, Bilhe P, Guedou JY, Lepoutre F (2013) Laser shock adhesion test (LASAT) of EB-PVD TBCs: towards an industrial application. Surf Coat Technol 237:305–31210.1016/j.surfcoat.2013.07.026 ↗
28. Faulhaber S, Mercer C, Moon M-W, Hutchinson JW, Evans AG (2006) Buckling delamination in compressed multilayers on curved substrates with accompanying ridge cracks. J Mech Phys Solids 54(5):1004–102810.1016/j.jmps.2005.11.005 ↗
29. Zset software, non-linear material and structure analysis suite. http://www.zset-software.com . Accessed 19 July 2019
30. Baufeld B, Bartsch M, Dalkilic S, Heinzelmann M (2005) Defect evolution in thermal barrier coating systems under multi-axial thermomechanical loading. Surf Coat Technol 200(5–6):1282–128610.1016/j.surfcoat.2005.07.098 ↗
31. White FM (1988) Heat and mass transfer. Addison-Wesley, Boston