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Experimental and numerical life prediction of thermally cycled thermal barrier coatings

Liu, Yan LU ; Persson, Christer LU and Wigren, J (2004) In Journal of Thermal Spray Technology 13(3). p.415-424
Abstract
This article addresses the predominant degradation modes and life prediction of a plasma-sprayed thermal barrier coating (TBC). The studied TBC system consists of an air-plasm a-sprayed bond coat and an air-plasma-sprayed, yttria partially stabilized zirconia top layer on a conventional Hastelloy X substrate. Thermal shock tests of air-sprayed TBC and pre-oxidized TBC specimens were conducted under different burner flame conditions at Volvo Aero Corporation (Trollhiittan, Sweden). Finite element models were used to simulate the thermal shock tests. Transient temperature distributions and thermal mismatch stresses in different layers of the coatings during thermal cycling were calculated. The roughness of the interface between the ceramic... (More)
This article addresses the predominant degradation modes and life prediction of a plasma-sprayed thermal barrier coating (TBC). The studied TBC system consists of an air-plasm a-sprayed bond coat and an air-plasma-sprayed, yttria partially stabilized zirconia top layer on a conventional Hastelloy X substrate. Thermal shock tests of air-sprayed TBC and pre-oxidized TBC specimens were conducted under different burner flame conditions at Volvo Aero Corporation (Trollhiittan, Sweden). Finite element models were used to simulate the thermal shock tests. Transient temperature distributions and thermal mismatch stresses in different layers of the coatings during thermal cycling were calculated. The roughness of the interface between the ceramic top coat and the bond coat was modeled through an ideally sinusoidal wavy surface. Bond coat oxidation was simulated through adding an aluminum oxide layer between the ceramic top coat and the bond coat. The calculated stresses indicated that interfacial delamination cracks, initiated in the ceramic top coat at the peak of the asperity of the interface, together with surface cracking, are the main reasons for coating failure. A phenomenological life prediction model for the coating was proposed. This model is accurate within a factor of (Less)
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author
organization
publishing date
type
Contribution to journal
publication status
published
subject
keywords
thermal shock tests, stress relaxation, prediction model, life, in-plane stress range, bond coat oxidation, finite element method
in
Journal of Thermal Spray Technology
volume
13
issue
3
pages
415 - 424
publisher
Springer
external identifiers
  • wos:000223928200010
  • scopus:4844229797
ISSN
1544-1016
DOI
10.1361/10599630420399
language
English
LU publication?
yes
id
21f4f769-1ac5-4ef3-b283-cf53a35f3fc0 (old id 267030)
date added to LUP
2007-10-24 20:16:37
date last changed
2017-09-17 05:09:02
@article{21f4f769-1ac5-4ef3-b283-cf53a35f3fc0,
  abstract     = {This article addresses the predominant degradation modes and life prediction of a plasma-sprayed thermal barrier coating (TBC). The studied TBC system consists of an air-plasm a-sprayed bond coat and an air-plasma-sprayed, yttria partially stabilized zirconia top layer on a conventional Hastelloy X substrate. Thermal shock tests of air-sprayed TBC and pre-oxidized TBC specimens were conducted under different burner flame conditions at Volvo Aero Corporation (Trollhiittan, Sweden). Finite element models were used to simulate the thermal shock tests. Transient temperature distributions and thermal mismatch stresses in different layers of the coatings during thermal cycling were calculated. The roughness of the interface between the ceramic top coat and the bond coat was modeled through an ideally sinusoidal wavy surface. Bond coat oxidation was simulated through adding an aluminum oxide layer between the ceramic top coat and the bond coat. The calculated stresses indicated that interfacial delamination cracks, initiated in the ceramic top coat at the peak of the asperity of the interface, together with surface cracking, are the main reasons for coating failure. A phenomenological life prediction model for the coating was proposed. This model is accurate within a factor of},
  author       = {Liu, Yan and Persson, Christer and Wigren, J},
  issn         = {1544-1016},
  keyword      = {thermal shock tests,stress relaxation,prediction model,life,in-plane stress range,bond coat oxidation,finite element method},
  language     = {eng},
  number       = {3},
  pages        = {415--424},
  publisher    = {Springer},
  series       = {Journal of Thermal Spray Technology},
  title        = {Experimental and numerical life prediction of thermally cycled thermal barrier coatings},
  url          = {http://dx.doi.org/10.1361/10599630420399},
  volume       = {13},
  year         = {2004},
}