Design and optimization of coating structure for plasma sprayed self-healing MgO coating via finite element method

Zhuang, Mingxiang; Yuan, Jian-Hui; Hu, Zhongchao; Li, Guangshu; Zhang, Huanyu; Zhang, Jiajia; Bin, Huang; Wang, Liang

doi:10.1016/j.ceramint.2020.09.084

Cited by 9 publications

(5 citation statements)

References 39 publications

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“…Yusof et al [ 150 ] simulated the effect of spherical and elliptic particles on the substrate by smooth particle hydrodynamics (SPH) and the Johnson–Cook model and found that the tensile stress in the coating deposited by elliptic particles would damage the quality of the coating; however, the compressive stress inside the coating deposited by spherical particles will increase the fatigue life of the coating. Zhuang et al [ 151 ] analysed the influence of the MgO coating thickness and convective heat transfer coefficient on the residual stress using the thermomechanical coupling module of ANSYS.…”

Section: Numerical Simulation Of the Polymer Composite Manufacturing ...mentioning

confidence: 99%

Manufacturing Technologies of Polymer Composites—A Review

Wang³

et al. 2023

Polymers

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Polymer composites have been widely used in the aviation, aerospace, automotive, military, medical, agricultural and industrial fields due to their excellent mechanical properties, heat resistance, flame retardant, impact resistance and corrosion resistance. In general, their manufacturing process is one of the key factors affecting the life cycle of polymer composites. This article provides an overview of typical manufacturing technologies, including surface coating, additive manufacturing and magnetic pulse powder compaction, which are normally used to reduce the failure behaviour of polymer composites in service so that the quality of composite products can be improved. Advanced polymer composite powder manufacturing processes, the processing mechanism and experimental methods are described, and the influence of different manufacturing processes on the moulding quality is revealed. This investigation can provide suitable methods for the selection of manufacturing technology to improve the quality of polymer composite products.

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Section: Numerical Simulation Of the Polymer Composite Manufacturing ...mentioning

confidence: 99%

Manufacturing Technologies of Polymer Composites—A Review

Wang³

et al. 2023

Polymers

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“…Therefore, the physical property parameters of the corresponding CMAS particles can be calculated by using the mixing law [6],…”

Section: Physical Properties Of Materialsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

“…Environmental impacts mainly concern damage of the TBCs by operating conditions, including thermal shock, high-temperature oxidation and particle erosion [5]. As shown in Figure 1, regardless of the failure modes of TBCs, it can be attributed to crack propagation and interface delamination [6]. As for blades in gas turbines applied in aviation propulsion or power generation, when the blades were operated under conditions full of foreign particles, especially silicate based particles in the air (possibly from volcanic ash, sand, concrete dust and other ways), these solid particles are sucked into the compressor together with the air in the engine intake and erode the interior of the engine at a certain speed [7].…”

Section: Introductionmentioning

confidence: 99%

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Effect of Morphology, Impact Velocity and Angle of the CaO-MgO-Al2O3-SiO2 (CMAS) Particle on the Erosion Behavior of Thermal Barrier Coatings (TBCs): A Finite Element Simulation Study

et al. 2022

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The erosion of the unmelted CaO-MgO-Al2O3-SiO2 (CMAS) particle is one of the dominating factors that causes microcracks in thermal barrier coatings (TBCs) when an aeroengine operates under actual service conditions. The microcracks provide a pathway for the erosion of the TBCs by the molten CMAS particles, which accelerates the failure of the coating. Herein a simplified model to mimic the erosion of YSZ (Y2O3 stabilized ZrO2) TBCs by the CMAS particles with high speed is proposed. The finite element method was utilized to systematically investigate the physical damage behaviors of the TBCs by the CMAS particles under various contact configurations, impact velocities and impact angles. We show that the contact configuration has a significant impact on the residual stress of the coating surfaces as well as the formation and types of microcracks. Furthermore, the increment of the erosion velocity gave rise to irreversible deformation around the point of contact, which aggravated the stress conditions of the top layer and led to the delamination failure of the coating. Finally, the larger the erosion angle, the more mechanical energy was converted into internal energy, which accumulated in the YSZ and caused it to finally delaminate.

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“…Therefore, in these two failure mechanisms, the thermal mismatch leads to the interface separation failure of the coating, and the effect of TGO can be ignored [42]. (6) There is no heat resistance at the interfaces between adjacent layers [43].…”

Section: Finite Element Simulation Modelmentioning

confidence: 99%

Optimization of the Thickness and Interface Structure of Al2O3-YAG/ZrO1.5-YO1.5-TaO1.5/8YSZ/NiCoCrAlY Multilayer Thermal Barrier Coatings: A Finite Element Simulation

Zhou

Cao

et al. 2022

Coatings

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Thermal barrier coatings (TBCs) prepared using the atmospheric plasma spraying method fail mainly due to coating delamination caused by thermal mismatch in the absence of high temperature assessment. In this study, the thickness optimization of multiple ceramic layers in a TBCs and the influence of the interface structure on the residual stress of the coating were investigated using a finite element simulation method. The results showed that varying the thickness of each layer of a TBCs with multiple ceramic layers affects the distribution and magnitude of the residual stress of the coating. Therefore, a reasonable range of thickness for each layer can be determined. The thickness of the bonding layer should be 110 μm, the thickness of YSZ layer should be about 270 μm, the thickness of tantalate layer should be about 70 μm, and the thickness of Al2O3-YAG layer should be about 100 μm. Simultaneously, the results show that a rough interface can be more effective in reducing the relief of stress concentrations compared to a smooth interface, but the stress values increase.

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Design and optimization of coating structure for plasma sprayed self-healing MgO coating via finite element method

Cited by 9 publications

References 39 publications

Manufacturing Technologies of Polymer Composites—A Review

Manufacturing Technologies of Polymer Composites—A Review

Effect of Morphology, Impact Velocity and Angle of the CaO-MgO-Al2O3-SiO2 (CMAS) Particle on the Erosion Behavior of Thermal Barrier Coatings (TBCs): A Finite Element Simulation Study

Optimization of the Thickness and Interface Structure of Al2O3-YAG/ZrO1.5-YO1.5-TaO1.5/8YSZ/NiCoCrAlY Multilayer Thermal Barrier Coatings: A Finite Element Simulation

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