Numerical study on effects of interfacial roughness and microcracks on stress distribution in thermal barrier coatings with temperature drop
This paper establishes a finite element model that includes the interface roughness characteristics to evaluate the stress concentration in the atmospheric plasma sprayed (APS) thermal barrier coatings (TBCs) with an uneven temperature field. We further scrutinize the effects of crack initiation at...
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| Language: | English |
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Elsevier
2024-11-01
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| Series: | Heliyon |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2405844024161981 |
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| author | Mengqi Yu Ningning Liu Ruifeng Dou Linjing Huang Jian Sun Zhi Wen Xunliang Liu |
| author_facet | Mengqi Yu Ningning Liu Ruifeng Dou Linjing Huang Jian Sun Zhi Wen Xunliang Liu |
| author_sort | Mengqi Yu |
| collection | DOAJ |
| description | This paper establishes a finite element model that includes the interface roughness characteristics to evaluate the stress concentration in the atmospheric plasma sprayed (APS) thermal barrier coatings (TBCs) with an uneven temperature field. We further scrutinize the effects of crack initiation at the interface between the thermally grown oxide (TGO) and the bond coat (BC) and in the ceramic top-coat (TC) on stress redistribution by introducing the debonding model for crack analysis. Results indicate that the interfacial residual stress σ22 achieves the critical value at the end of the cooling stage. As the temperature drop intensifies, the σ22 declines at the interface while it escalates within the TC. However, the interfacial crack propagation results in the redistribution of stress in the TBCs, and the σ22 changes from tensile stress to compressive stress in the peak of the TC. The propagation rate of the interfacial crack accelerates with a smaller temperature difference and a thicker initial TGO. When the TGO/BC interfacial morphology is uniform, the crack growth rate is the most rapid. The stress redistribution leads to an off-peak tensile stress concentration area in the TC and increased maximum tensile stress near the horizontal micro-crack tip. The concentration area of σ11 occurs in the TC above the peak of the interface, indicating that the vertical crack in the TC is likely to initiate above the peak. |
| format | Article |
| id | doaj-art-088964472e7d47d397b7dddaa21a7c59 |
| institution | OA Journals |
| issn | 2405-8440 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Heliyon |
| spelling | doaj-art-088964472e7d47d397b7dddaa21a7c592025-08-20T02:07:31ZengElsevierHeliyon2405-84402024-11-011022e4016710.1016/j.heliyon.2024.e40167Numerical study on effects of interfacial roughness and microcracks on stress distribution in thermal barrier coatings with temperature dropMengqi Yu0Ningning Liu1Ruifeng Dou2Linjing Huang3Jian Sun4Zhi Wen5Xunliang Liu6School of Energy and Environmental Engineering, University of Science and Technology Beijing, Beijing, 100083, People's Republic of ChinaSchool of Energy and Environmental Engineering, University of Science and Technology Beijing, Beijing, 100083, People's Republic of China; China United Gas Turbine Technology Co., LTD, Beijing, 100016, People's Republic of ChinaSchool of Energy and Environmental Engineering, University of Science and Technology Beijing, Beijing, 100083, People's Republic of China; Corresponding author.China United Gas Turbine Technology Co., LTD, Beijing, 100016, People's Republic of ChinaChina United Gas Turbine Technology Co., LTD, Beijing, 100016, People's Republic of ChinaSchool of Energy and Environmental Engineering, University of Science and Technology Beijing, Beijing, 100083, People's Republic of ChinaSchool of Energy and Environmental Engineering, University of Science and Technology Beijing, Beijing, 100083, People's Republic of ChinaThis paper establishes a finite element model that includes the interface roughness characteristics to evaluate the stress concentration in the atmospheric plasma sprayed (APS) thermal barrier coatings (TBCs) with an uneven temperature field. We further scrutinize the effects of crack initiation at the interface between the thermally grown oxide (TGO) and the bond coat (BC) and in the ceramic top-coat (TC) on stress redistribution by introducing the debonding model for crack analysis. Results indicate that the interfacial residual stress σ22 achieves the critical value at the end of the cooling stage. As the temperature drop intensifies, the σ22 declines at the interface while it escalates within the TC. However, the interfacial crack propagation results in the redistribution of stress in the TBCs, and the σ22 changes from tensile stress to compressive stress in the peak of the TC. The propagation rate of the interfacial crack accelerates with a smaller temperature difference and a thicker initial TGO. When the TGO/BC interfacial morphology is uniform, the crack growth rate is the most rapid. The stress redistribution leads to an off-peak tensile stress concentration area in the TC and increased maximum tensile stress near the horizontal micro-crack tip. The concentration area of σ11 occurs in the TC above the peak of the interface, indicating that the vertical crack in the TC is likely to initiate above the peak.http://www.sciencedirect.com/science/article/pii/S2405844024161981Thermal barrier coatingsTemperature differenceInterface morphologyDebondingCrack propagation |
| spellingShingle | Mengqi Yu Ningning Liu Ruifeng Dou Linjing Huang Jian Sun Zhi Wen Xunliang Liu Numerical study on effects of interfacial roughness and microcracks on stress distribution in thermal barrier coatings with temperature drop Heliyon Thermal barrier coatings Temperature difference Interface morphology Debonding Crack propagation |
| title | Numerical study on effects of interfacial roughness and microcracks on stress distribution in thermal barrier coatings with temperature drop |
| title_full | Numerical study on effects of interfacial roughness and microcracks on stress distribution in thermal barrier coatings with temperature drop |
| title_fullStr | Numerical study on effects of interfacial roughness and microcracks on stress distribution in thermal barrier coatings with temperature drop |
| title_full_unstemmed | Numerical study on effects of interfacial roughness and microcracks on stress distribution in thermal barrier coatings with temperature drop |
| title_short | Numerical study on effects of interfacial roughness and microcracks on stress distribution in thermal barrier coatings with temperature drop |
| title_sort | numerical study on effects of interfacial roughness and microcracks on stress distribution in thermal barrier coatings with temperature drop |
| topic | Thermal barrier coatings Temperature difference Interface morphology Debonding Crack propagation |
| url | http://www.sciencedirect.com/science/article/pii/S2405844024161981 |
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