journal article·2021-12

Analysis of crack initiation and propagation in Thermal Barrier Coatings using SEM-Based geometrical model with extended finite element method

Ahmed Abdelgawad, Khaled Al-Athel, Jafar Albinmousa

Ceramics International· Volume 47· Issue 23
Publisher page

Abstract

Abstract Thermal Barrier Coatings (TBC) are widely used to protect the metallic components that operate at harsh conditions of elevated temperatures and oxidizing environments. Thermally grown oxide (TGO) causes cracks formation in the top coat (TC) that may lead to spallation failure of TBC. This work investigates effect of pores and TGO thickness on crack initiation and propagation due to thermal mismatch between TBC layers. Image processing is used to convert an SEM image, including pores, into a finite element (FE) model. An FE model using XFEM implemented in ABAQUS was developed to investigate crack initiation and propagation for various TGO thicknesses considering the effect of plastic deformation of BC, TGO and substrate. Results show that presence of pores changes the critical sites for crack initiation from the TC/TGO interface to be around the pores within the TC. Crack initiation temperatures and crack lengths were found to be affected with both TGO thickness and pores.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: High-Temperature Coating Behaviors · Advanced ceramic materials synthesis · Thermal properties of materials

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

References (49)

Show source-provided references
1. “Thermal barrier coatings for high temperature applications – a short review10.1016/j.matpr.2020.08.017 ↗
2. Advances in numerical modeling of environmental barrier coating systems for gas turbines10.1016/j.jeurceramsoc.2020.03.036 ↗
3. Influence of material parameters on the interfacial crack growth in thermal barrier coating system10.1016/j.ceramint.2019.01.150 ↗
4. Phase transfomation stress Field due to hot corrosion in the top coat of TBC
5. Development of improved bond coat for enhanced turbine durability
6. “Numerical analysis of the influence of pore microstructure on thermal conductivity and Young's modulus of thermal barrier coating10.1016/j.ceramint.2020.06.214 ↗
7. Fundamental concepts
8. Application of zirconia in dentistry: biological, mechanical and optical considerations
9. Microcrack nucleation in thermal barrier coating systems10.1016/j.engfracmech.2008.12.010 ↗
10. Numerical investigation into the effect of splats and pores on the thermal fracture of air plasma-sprayed thermal barrier coatings10.1007/s11666-019-00949-y ↗
11. Effect of splat-interface discontinuity on effective thermal conductivity of plasma sprayed thermal barrier coating10.1016/j.ceramint.2019.10.215 ↗
12. Effect of five kinds of pores shape on thermal stress properties of thermal barrier coatings by finite element method10.1016/j.ceramint.2017.04.139 ↗
13. Mechanical analysis and modeling of porous thermal barrier coatings10.1016/j.apsusc.2020.145706 ↗
14. Assessment of TBC systems failure mechanisms using a fracture mechanics approach10.1016/j.actamat.2005.06.003 ↗
15. Finite element analysis of stress distribution in thermal barrier coatings10.1016/j.surfcoat.2008.06.178 ↗
16. Finite element simulation of interface cracks in thermal barrier coatings10.1016/j.commatsci.2012.02.044 ↗
17. Effect of residual stresses and prediction of possible failure mechanisms on thermal barrier coating system by finite element method
18. Simulation of the effect of material properties and interface roughness on the stress distribution in thermal barrier coatings using finite element method10.1016/j.matdes.2009.08.005 ↗
19. Finite element modeling of the different failure mechanisms of a plasma sprayed thermal barrier coatings system
20. Modeling decohesion of a top-coat from a thermally-growing oxide in a thermal barrier coating10.1016/j.surfcoat.2013.02.005 ↗
21. Simulation of failure of air plasma sprayed thermal barrier coating due to interfacial and bulk cracks using surface-based cohesive interaction and extended finite element method10.1177/0309324715615746 ↗
22. Influence of interface morphology of transition layer on the residual stresses of plasma sprayed ZrC-based coatings examined by finite element simulations10.1016/j.ceramint.2019.03.235 ↗
23. Dynamic crack growth mechanism and lifetime assessment in plasma sprayed thermal barrier system upon temperature cycling10.1016/j.ceramint.2019.04.223 ↗
24. Structural parameter study on stress intensity factors of interfacial crack in thermal barrier coatings10.1016/j.ceramint.2021.02.014 ↗
25. Model construction and effect of thermally grown oxide dynamic growth on distribution of thermal barrier coatings10.1016/j.ceramint.2021.03.161 ↗
26. On crack evolution with texturization of bonding layer in thermal barrier coating
27. Jonnalagadda · 2017
28. A methodology to model the complex morphology of rough interfaces10.1016/j.ijsolstr.2014.04.015 ↗
29. Influence of topcoat-bondcoat interface roughness on stresses and lifetime in thermal barrier coatings10.1007/s11666-013-0022-9 ↗
30. Gupta · 2010
31. Microstructure image-based modeling of fracture in continuous fiber-reinforced ceramic matrix composites
32. Image-based extended finite element modeling of thermal barrier coatings10.1016/j.surfcoat.2006.04.003 ↗
33. Finite element analysis of the effect of thermal cycles and ageing on the interface delamination of plasma sprayed thermal barrier coatings10.1016/j.surfcoat.2019.06.093 ↗
34. Spallation of thermal barrier coatings with real thermally grown oxide morphology under thermal stress10.1016/j.matdes.2018.03.019 ↗
35. Finite element simulation of residual stress and failure mechanism in plasma sprayed thermal barrier coatings using actual microstructure as the representative volume10.1016/j.surfcoat.2016.02.028 ↗
36. Effect of TGO thickness , pores , and creep on the developed residual stresses in thermal barrier coatings under cyclic loading using SEM image-based finite element model
37. “Modelling of TBC system failure : stress distribution as a function of TGO thickness and thermal expansion mismatch10.1016/j.engfailanal.2004.12.027 ↗
38. Failure mechanisms associated with the thermally grown oxide in plasma-spray thermal barrier coatings10.1016/S1359-6454(00)00171-3 ↗
39. “Modeling of thermal properties and failure of thermal barrier coatings with the use of finite element methods : a review10.1016/j.jeurceramsoc.2015.12.038 ↗
40. The partition of unity finite element method: basic theory and applications10.1016/S0045-7825(96)01087-0 ↗
41. hp-Meshless cloud method
42. A method for dynamic crack and shear band propagation with phantom nodes10.1002/nme.1652 ↗
43. Computational investigation of porosity effects on fracture behavior of thermal barrier coatings10.1016/j.ceramint.2019.07.031 ↗
44. Sharma · 2007
45. A parametric study of the stress state of thermal barrier coatings part I: creep relaxation
46. The influence of bondcoat and topcoat mechanical properties on stress development in thermal barrier coating systems10.1016/j.actamat.2009.01.017 ↗
47. Modelling the high temperature behaviour of TBCs using sequentially coupled microstructural-mechanical FE analyses10.1016/j.msea.2009.02.006 ↗
48. “Young's modulus, flexural strength, and fracture of yttria-stabilized zirconia versus temperature10.1111/j.1151-2916.1997.tb02920.x ↗
49. A finite element method for the simulation of strong and weak discontinuities in solid mechanics10.1016/j.cma.2003.12.041 ↗