A Theoretical Model for Predicting Residual Stress Generation in Fabrication Process of Double-Ceramic-Layer Thermal Barrier Coating System

Song, Yan; Wu, Weijie; Xie, Feng; Liu, Yilun; Wang, Zhihui

doi:10.1371/journal.pone.0169738

Cited by 12 publications

(8 citation statements)

References 38 publications

(43 reference statements)

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“…Song and Y.C. Tsu’s studies [ 34 , 35 , 36 ], WRS generated in the single-layer cladding and substrate after the deposition of cladding layer in this study is shown as follows.…”

Section: Resultsmentioning

confidence: 81%

Evolution of Welding Residual Stresses within Cladding and Substrate during Electroslag Strip Cladding

Qin

Cheng

et al. 2020

Materials

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Hydrogenation reactors are important oil-refining equipment that operate in high-temperature and high-pressure hydrogen environments and are commonly composed of 2.25Cr–1Mo–0.25V steel. For a hydrogenation reactor with a plate-welding structure, the processes and effects of welding residual stress (WRS) are very complicated due to the complexity of the welding structure. These complex welding residual stress distributions affect the service life of the equipment. This study investigates the evolution of welding residual stress during weld-overlay cladding for hydrogenation reactors using the finite element method (FEM). A blind hole method is applied to verify the proposed model. Unlike the classical model, WRS distribution in a cladding/substrate system in this study was found to be divided into three regions: the cladding layer, the stress-affected layer (SAL), and the substrate in this study. The SAL is defined as region coupling affected by the stresses of the cladding layer and substrate at the same time. The evolution of residual stress in these three regions was thoroughly analyzed in three steps with respect to the plastic-strain state of the SAL. Residual stress was rapidly generated in Stage 1, reaching about −440 MPa compression stress in the SAL region at the end of this stage after 2.5 s. After cooling for 154 s, at the end of Stage 2, the WRS distribution was fundamentally shaped except for in the cladding layer. The interface between the cladding layer and substrate is the most heavily damaged region due to the severe stress gradient and drastic change in WRS during the welding process. The effects of substrate thickness and preheat temperature were evaluated. The final WRS in the cladding layer first increased with the increase in substrate thickness, and then started to decline when substrate thickness reached a large-enough value. WRS magnitudes in the substrate and SAL decreased with the increase in preheat temperature and substrate thickness. Compressive WRS in the cladding layer, on the other hand, increased with the increase in preheat temperature.

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“…Song and Y.C. Tsu’s studies [ 34 , 35 , 36 ], WRS generated in the single-layer cladding and substrate after the deposition of cladding layer in this study is shown as follows.…”

Section: Resultsmentioning

confidence: 81%

Evolution of Welding Residual Stresses within Cladding and Substrate during Electroslag Strip Cladding

Qin

Cheng

et al. 2020

Materials

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“…The influence of critical process parameters on the residual stresses was also investigated, and the model was successfully verified through comparisons with FE results. [ 147 ] In a recent study, Jafarpour et al investigated the residual stress distribution in CNF/epoxy nanocomposites with different CNF patterns, using Halpin−Tsai−Schapery (HTS) and Mori−Tanaka−Schapery (MTS) and FE models. The results suggested that HTS and MTS models can adequately predict residual stresses in nanocomposites with random CNT distribution patterns, while for specific patterns, the FE model is recommended.…”

Section: Methodsmentioning

confidence: 99%

Residual Stress in Engineering Materials: A Review

et al. 2021

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The accurate determination of residual stresses has a crucial role in understanding the complex interactions between microstructure, mechanical state, mode(s) of failure, and structural integrity. Moreover, the residual stress management concept contributes to industrial applications, aiming to improve the product's service performance and life cycle. In this regard, the industry requests rapid, efficient, and modern methods to identify and control the residual stress state. This review article contains three main sections. The first section covers different residual stress determination methods and reports the advancements over the recent decade. The second section includes the role of residual stresses in the performance of a broad range of materials including metallic alloys, polymers, ceramics, composites, and biomaterials. This is presented by classifying different science areas dealing with residual stresses into two main groups, including “origins” and “effects” of residual stresses. The range of topics covered are “welding, machining, curing/cooling, and spray coating processes,” “medical and dental sciences,” and “fatigue and fracture mechanisms.” The third section summarizes various strategies to effectively control residual stresses through different manufacturing procedures. It is hoped that the data provided herein serves as a valuable up‐to‐date reference for engineers and scientists in the field of residual stress.

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“…Increasing the phase stability while decreasing the overall thermal conductivity and thermal expansion mismatch can slow oxidation rates and, thus, potential layer spallation in the TBC. Many studies have shown zirconate DCL coatings to be a viable option for improving the overall lifetimes and performance of TBCs in various applications. − …”

Section: Design Of Thermal Barrier Coatingsmentioning

confidence: 99%

Thermal Barrier Coatings Overview: Design, Manufacturing, and Applications in High-Temperature Industries

Mondal

Nuñez

Myer

et al. 2021

Ind. Eng. Chem. Res.

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Today's competitive world economy is creating an indispensable demand for increased efficiency of engineering components that operate in harsh environments (i.e., very high-temperature, corrosive, or neutron irradiation environments), for applications in the energy, automotive, aerospace, electronics, and power industries. Increased research is being done on thermal barrier coatings (TBCs) for protecting such components, since the versatility of manufacturing techniques and the scale of deployment result in increased life, economics, performance, and durability. This review focuses on the advances that led to using TBCs for component life extension and, more recently, as an integral part of advanced component design for high-temperature and other types of harsh environments, such as those found in nuclear-related applications. Factors that led to state-of-the-art advanced coating-fabrication techniques [e.g., electron-beam physical vapor deposition (EB-PVD), plasma spray deposition, and electrophoretically deposited TBCs, as well as functionally graded material (FGM) manufacturing] have also been emphasized in current coating R&D. This review explores the current state of TBCs, i.e., the latest advances regarding their fabrication and performance, associated challenges, and recommendations for their future use in aerospace, nuclear, high-temperature, or otherwise harsh environments.

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A Theoretical Model for Predicting Residual Stress Generation in Fabrication Process of Double-Ceramic-Layer Thermal Barrier Coating System

Cited by 12 publications

References 38 publications

Evolution of Welding Residual Stresses within Cladding and Substrate during Electroslag Strip Cladding

Evolution of Welding Residual Stresses within Cladding and Substrate during Electroslag Strip Cladding

Residual Stress in Engineering Materials: A Review

Thermal Barrier Coatings Overview: Design, Manufacturing, and Applications in High-Temperature Industries

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