Design and optimization of coating structure for the thermal barrier coatings fabricated by atmospheric plasma spraying via finite element method

Wang, Li; Zhong, Xinghua; Zhao, Yingxue; Tao, Shunyan; Zhang, W.; Wang, Y.; Sun, Xiao‐Guang

doi:10.1016/j.jascer.2014.01.006

Cited by 40 publications

(16 citation statements)

References 64 publications

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“…Table 10. Comparison of five-phase results with experimental results [50,62,78,80,82,83]. Figure 20 provide an overall comparison of the three different YSZ coatings, HOSP, FC and AS.…”

Section: Validation Of the Calculated Resultsmentioning

confidence: 97%

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Modelling Thermal Conductivity of Porous Thermal Barrier Coatings

2019

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Thermal conductivity of porous thermal barrier coatings was evaluated using a newly developed five-phase model. It was demonstrated that porosities distributed in coating strongly affect thermal conductivity. The decisive reason for this change in thermal conductivity can be traced back to defect morphology and its orientation, depending on the coating deposition technique and process parameters used during deposition. In this paper, the Bruggeman’s two-phase model was used as a reference, and a five-phase model was developed to evaluate the thermal conductivity of porous coatings. This approach uses microstructural details of the shape, size, orientation and volumetric fraction of defects of coatings as input parameters. The proposed model can predict thermal conductivity values better than the previous two-phase model.

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“…Table 10. Comparison of five-phase results with experimental results [50,62,78,80,82,83]. Figure 20 provide an overall comparison of the three different YSZ coatings, HOSP, FC and AS.…”

Section: Validation Of the Calculated Resultsmentioning

confidence: 97%

“…Analytical models use detailed information from previously available information to meet the complex design needs of thermal barrier coatings [62]. The thermal conductivity is strongly influenced by entrapped air or liquid in the pores.…”

Section: Proposed Five-phase Model For Thermal Conductivitymentioning

confidence: 99%

Modelling Thermal Conductivity of Porous Thermal Barrier Coatings

2019

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“…The residual stresses that can be generated due to differences in thermal expansion between coatings and substrates have been considered in various levels of complexity ranging from uniaxial analytical elastic models that consider only thermal mismatch strains to finite element modeling that consider thermal mismatch strains as well as transient effects of the coating application process, for example (Ref [27][28][29][30][31]. A simple analytical approach considering only elastic strains generated by thermal mismatch was used for an initial evaluation, using available data and these materials.…”

Section: Resultsmentioning

confidence: 99%

Influences of Processing and Fatigue Cycling on Residual Stresses in a NiCrY-Coated Powder Metallurgy Disk Superalloy

Gabb

Rogers

Nesbitt

et al. 2017

J. of Materi Eng and Perform

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Oxidation and corrosion can attack superalloy disk surfaces exposed to increasing operating temperatures in some turbine engine environments. Any potential protective coatings must also be resistant to harmful fatigue cracking during service. The objective of this study was to investigate how residual stresses evolve in one such coating. Fatigue specimens of a powder metallurgy-processed disk superalloy were coated with a NiCrY coating, shot peened, and then subjected to fatigue in air at room and high temperatures. The effects of this processing and fatigue cycling on axial residual stresses and other aspects of the coating were assessed. While shot peening did induce beneficial compressive residual stresses in the coating and substrate, these stresses relaxed in the coating with subsequent heating. Several cast alloys having compositions near the coating were subjected to thermal expansion and tensile stress relaxation tests to help explain this response of residual stresses in the coating. For the coated fatigue specimens, this response contributed to earlier cracking of the coating than for the uncoated surface during long intervals of cycling at 760°C. Yet, substantial compressive residual stresses still remained in the substrate adjacent to the coating, which were sufficient to suppress fatigue cracking there. The coating continued to protect the substrate from hot corrosion pitting, even after fatigue cracks initiated in the coating.

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“…The temperature-dependent creep constants "A" and "n" for YSZ, Inconel 718, and NiCoCrAlY bond coat made using HVOF and APS [23,24] are noted in Table 1. The materials properties of YSZ [25], bond coat [25], and substrate Inconel 718 [26] as listed in Table 2.…”

Section: Properties Of Materials Used In the Fe Modelmentioning

confidence: 99%

“…Temperature-dependent creep constants used in the FE model[23,24]. Temperature-dependent material properties used in the FE model[25,26].…”

mentioning

confidence: 99%

Experimental and Modeling Studies of Bond Coat Species Effect on Microstructure Evolution in EB-PVD Thermal Barrier Coatings in Cyclic Thermal Environments

Lyu

Gulhane

et al. 2019

Coatings

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In this work, the effects of bond coat species on the thermal barrier coating (TBC) microstructure are investigated under thermal cyclic conditions. The TBC samples are prepared by electron beam-physical vapor deposition with two species of bond coats prepared by either air-plasma spray (APS) or high-velocity oxygen fuel (HVOF) methods. The TBC samples are evaluated in a variety of thermal cyclic conditions, including flame thermal fatigue (FTF), cyclic furnace thermal fatigue (CFTF), and thermal shock (TS) tests. In FTF test, the interface microstructures of TBC samples show a sound condition without any delamination or cracking. In CFTF and TS tests, the TBCs with the HVOF bond coat demonstrate better thermal durability than that by APS. In parallel with the experiments, a finite element (FE) model is developed. Using a transient thermal analysis, the high-temperature creep-fatigue behavior of the TBC samples is simulated similar to the conditions used in CFTF test. The FE simulation predicts a lower equivalent stress at the interface between the top coat and bond coat in bond coat prepared using HVOF compared with APS, suggesting a longer cyclic life of the coating with the HVOF bond coat, which is consistent with the experimental observation.

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Design and optimization of coating structure for the thermal barrier coatings fabricated by atmospheric plasma spraying via finite element method

Cited by 40 publications

References 64 publications

Modelling Thermal Conductivity of Porous Thermal Barrier Coatings

Modelling Thermal Conductivity of Porous Thermal Barrier Coatings

Influences of Processing and Fatigue Cycling on Residual Stresses in a NiCrY-Coated Powder Metallurgy Disk Superalloy

Experimental and Modeling Studies of Bond Coat Species Effect on Microstructure Evolution in EB-PVD Thermal Barrier Coatings in Cyclic Thermal Environments

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