Stress evolution in thermal barrier coatings for rocket engine applications

Bäker, Martin; Fiedler, Torben; Rösler, Joachim

doi:10.1186/s40759-015-0005-2

Cited by 12 publications

(9 citation statements)

References 19 publications

(14 reference statements)

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“…It was observed on the different specimens. A compressive stress state in the hole enabled deviations of cracks in the coating [34] Thus, the time for TC spallation was limited by the coating mechanical properties due to this failure mode. Indeed, S80-textured specimens have a larger adhesion strength (see Fig.…”

Section: Time To Spallation Of the Top-coat Under High Temperature Oxmentioning

confidence: 99%

High temperature durability of a bond-coatless plasma-sprayed thermal barrier coating system with laser textured Ni-based single crystal substrate

Kromer

Cormier

Costil

et al. 2018

Surface and Coatings Technology

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Thermal barrier coating systems are usually build-up with bond coats to ensure a good adhesion of the ceramic top coat and to protect the substrate against oxidation and corrosion. Such system is often subjected to complex thermo-mechanical loading. Because of the very different damage processes encountered during service operations, a simplified system was investigated by removing the bond-coat. Recently adhesion bond strength was enhanced using laser surface texturing of the substrate in thermal spraying processes. Atmospheric plasma spray yttria-stabilized-zirconia thermal barrier coating system was deposited on the Ni-based AM1 single crystalline superalloy without bond coat. Adhesion bond strength was already increased compared to conventional processing method. Top coat durability was evaluated at high temperature and damage mechanisms were studied. Isothermal and cyclic oxidation tests showed durability of 1000 h and 400 cycles at 1100°C. The oxidation mechanisms at the substrate/top coat interface changed due to fast solidification during the laser texturing process. Then, TBC system was studied under high temperature mechanical solicitation in tension creep. The textured interfaces were not damaged after 1% creep strain while top-coat/substrate interfacial cracking was observed for grit-blasted specimens. Moreover, no preferential crack development in the substrate was observed. Patterns provided an enhanced adhesion by changing the stress distribution near the interface.

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Section: Time To Spallation Of the Top-coat Under High Temperature Oxmentioning

confidence: 99%

High temperature durability of a bond-coatless plasma-sprayed thermal barrier coating system with laser textured Ni-based single crystal substrate

Kromer

Cormier

Costil

et al. 2018

Surface and Coatings Technology

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“…The coatings designed in Sect. 3 reach surface temperatures of up to 1350 K. It had previously been assumed [37] that the maximum tolerable temperature of the top-coat surface is 1423 K, but experimental evidence was still missing.…”

Section: Arc Heated Hypersonic Wind Tunnelmentioning

confidence: 99%

Mechanical Integrity of Thermal Barrier Coatings: Coating Development and Micromechanics

Fiedler

Rösler

Bäker

et al. 2020

Notes on Numerical Fluid Mechanics and Multidisciplinary Design

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To protect the copper liners of liquid-fuel rocket combustion chambers, a thermal barrier coating can be applied. Previously, a new metallic coating system was developed, consisting of a NiCuCrAl bond-coat and a Rene 80 top-coat, applied with high velocity oxyfuel spray (HVOF). The coatings are tested in laser cycling experiments to develop a detailed failure model, and critical loads for coating failure were defined. In this work, a coating system is designed for a generic engine to demonstrate the benefits of TBCs in rocket engines, and the mechanical loads and possible coating failure are analysed. Finally, the coatings are tested in a hypersonic wind tunnel with surface temperatures of 1350 K and above, where no coating failure was observed. Furthermore, cyclic experiments with a subscale combustion chamber were carried out. With a diffusion heat treatment, no large-scale coating delamination was observed, but the coating cracked vertically due to large cooling-induced stresses. These cracks are inevitable in rocket engines due to the very large thermal-strain differences between hot coating and cooled substrate. It is supposed that the cracks can be tolerated in rocket-engine application.

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“…The intent of the authors for the future is also to use anisotropic damage models for simulations involving thermal barrier coatings. The thermomechanical material parameters for the copper alloy are chosen according to Kowollik et al [13] with the only difference that the coefficient of thermal expansion is adopted from Baeker et al [18] to be now temperature dependent. The nickel material behaviour only plays a minor role and is therefore modelled as linear elastic (cf.…”

Section: Materials Modellingmentioning

confidence: 99%

“…Kowollik et al [13]). The material behaviour of the TBC is modelled by an ideal elastoplastic material law as it was already done in Baeker et al [18]. The material parameters for the TBC were adopted from the bond coat material (NiCuCrAl).…”

Section: Materials Modellingmentioning

confidence: 99%

Modelling Thermal Barrier Coatings and Their Influence on the Lifetime of Rocket Engine Nozzle Structures

Fassin¹,

Wulfinghoff²,

Reese³

2016

Proceedings of the VII European Congress on Computational Methods in Applied Sciences and Engineering (ECCOMAS Congress 2016)

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Stress evolution in thermal barrier coatings for rocket engine applications

Cited by 12 publications

References 19 publications

High temperature durability of a bond-coatless plasma-sprayed thermal barrier coating system with laser textured Ni-based single crystal substrate

High temperature durability of a bond-coatless plasma-sprayed thermal barrier coating system with laser textured Ni-based single crystal substrate

Mechanical Integrity of Thermal Barrier Coatings: Coating Development and Micromechanics

Modelling Thermal Barrier Coatings and Their Influence on the Lifetime of Rocket Engine Nozzle Structures

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