The effect of thermal loading waveform on the failure mechanism of atmospheric-plasma-sprayed thermal barrier coating system

Article
  • 20 Downloads

Abstract

The hot-end components of gas turbine engines in the serviced condition usually suffer from the thermal cycle loading effect. Thermal barrier coating (TBCs) have been used as a protective coating to prevent degradation during practical applications. In the current work, the influence of a loading waveform on the failure mechanism of an atmospheric plasma-sprayed TBCs is investigated at an elevated temperature. The samples under the trapezoidal loading condition present a lower thermal cycling fatigue lifetime than that under the triangular loading condition. Moreover, cracks in the TBCs samples under the triangular loading condition are initiated from the defects on the top coat formed during preparation, and cracks under the trapezoidal loading condition preferentially occur at the thermally grown oxide-top coat interface due to higher stress at the interface. Our results demonstrate that the thermal loading waveform should be carefully designed to characterize the in-service condition of hot-end components.

Keywords

coating loading waveform thermal-fatigue air-plasma-sprayed 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Miller R A. Current status of thermal barrier coatings—An overview. Surf Coat Tech, 1987, 30: 1–11CrossRefGoogle Scholar
  2. 2.
    Miller R A. Thermal barrier coatings for aircraft engines: History and directions. J Therm Spray Tech, 1997, 6: 35–42CrossRefGoogle Scholar
  3. 3.
    Padture N P, Gell M, Jordan E H. Thermal barrier coatings for gasturbine engine applications. Science, 2002, 296: 280–284CrossRefGoogle Scholar
  4. 4.
    Rösler J, Bäker M, Volgmann M. Stress state and failure mechanisms of thermal barrier coatings: Role of creep in thermally grown oxide. Acta Mater, 2001, 49: 3659–3670CrossRefGoogle Scholar
  5. 5.
    Wu H X, Ma Z, Liu L, et al. Thermal cycling behavior and bonding strength of single-ceramic-layer Sm2Zr2O7 and double-ceramic-layer Sm2Zr2O7/8YSZ thermal barrier coatings deposited by atmospheric plasma spraying. Ceram Int, 2016, 42: 12922–12927CrossRefGoogle Scholar
  6. 6.
    Richer P, Yandouzi M, Beauvais L, et al. Oxidation behaviour of CoNiCrAlY bond coats produced by plasma, HVOF and cold gas dynamic spraying. Surf Coat Tech, 2010, 204: 3962–3974CrossRefGoogle Scholar
  7. 7.
    Schlichting K W, Padture N P, Jordan E H, et al. Failure modes in plasma-sprayed thermal barrier coatings. Mater Sci Eng-A, 2003, 342: 120–130CrossRefGoogle Scholar
  8. 8.
    Mahade S, Curry N, Björklund S, et al. Failure analysis of Gd2Zr2O7/YSZ multi-layered thermal barrier coatings subjected to thermal cyclic fatigue. J Alloys Compd, 2016, 689: 1011–1019CrossRefGoogle Scholar
  9. 9.
    Rabiei A, Evans A G. Failure mechanisms associated with the thermally grown oxide in plasma-sprayed thermal barrier coatings. Acta Mater, 2000, 48: 3963–3976CrossRefGoogle Scholar
  10. 10.
    Giolli C, Scrivani A, Rizzi G, et al. Failure mechanism for thermal fatigue of thermal barrier coating systems. J Therm Spray Tech, 2009, 18: 223–230CrossRefGoogle Scholar
  11. 11.
    Jinnestrand M, Brodin H. Crack initiation and propagation in air plasma sprayed thermal barrier coatings, testing and mathematical modelling of low cycle fatigue behaviour. Mater Sci Eng-A, 2004, 379: 45–57CrossRefGoogle Scholar
  12. 12.
    Khan A N, Lu J. Behavior of air plasma sprayed thermal barrier coatings, subject to intense thermal cycling. Surf Coat Tech, 2003, 166: 37–43CrossRefGoogle Scholar
  13. 13.
    Ogawa K, Ito K, Shoji T, et al. Effects of Ce and Si additions to CoNiCrAlY bond coat materials on oxidation behavior and crack propagation of thermal barrier coatings. J Thermal Spray Tech, 2006, 15: 640–651CrossRefGoogle Scholar
  14. 14.
    Shillington E A G, Clarke D R. Spalling failure of a thermal barrier coating associated with Aluminum depletion in the bond-coat. Acta Mater, 1999, 47: 1297–1305CrossRefGoogle Scholar
  15. 15.
    Haynes J A, Ferber M K, Porter W D. Thermal cycling behavior of plasma-sprayed thermal barrier coatings with various MCrAIX bond coats. J Thermal Spray Tech, 2000, 9: 38–48CrossRefGoogle Scholar
  16. 16.
    Khan A N, Lu J. Thermal cyclic behavior of air plasma sprayed thermal barrier coatings sprayed on stainless steel substrates. Surf Coat Tech, 2007, 201: 4653–4658CrossRefGoogle Scholar
  17. 17.
    Liu D, Seraffon M, Flewitt P E J, et al. Effect of substrate curvature on residual stresses and failure modes of an air plasma sprayed thermal barrier coating system. J Eur Cer Soc, 2013, 33: 3345–3357CrossRefGoogle Scholar
  18. 18.
    Tzimas E, Müllejans H, Peteves S D, et al. Failure of thermal barrier coating systems under cyclic thermomechanical loading. Acta Mater, 2000, 48: 4699–4707CrossRefGoogle Scholar
  19. 19.
    Saucedo-Mora L, Slámečka K, Thandavamoorthy U, et al. Multi-scale modeling of damage development in a thermal barrier coating. Surf Coat Tech, 2015, 276: 399–407CrossRefGoogle Scholar
  20. 20.
    Trunova O, Beck T, Herzog R, et al. Damage mechanisms and lifetime behavior of plasma sprayed thermal barrier coating systems for gas turbines—Part I: Experiments. Surf Coat Tech, 2008, 202: 5027–5032CrossRefGoogle Scholar
  21. 21.
    Che C, Wu G Q, Qi H Y, et al. Uneven growth of thermally grown oxide and stress distribution in plasma-sprayed thermal barrier coatings. Surf Coat Tech, 2009, 203: 3088–3091CrossRefGoogle Scholar
  22. 22.
    Yamazaki Y, Kuga S I, Yoshida T. Evaluation of interfacial strength by an instrumented indentation method and its application to an actual TBC vane. Acta Metall Sin, 2011, 24: 109–117Google Scholar
  23. 23.
    Chang G C, Phucharoen W, Miller R A. Behavior of thermal barrier coatings for advanced gas turbine blades. Surf Coat Tech, 1987, 30: 13–28CrossRefGoogle Scholar
  24. 24.
    Slámečka K, Skalka P, Pokluda J, et al. Finite element simulation of stresses in a plasma-sprayed thermal barrier coating with an irregular top-coat/bond-coat interface. Surf Coat Tech, 2016, 304: 574–583CrossRefGoogle Scholar
  25. 25.
    Chantikul P, Lawn B R, Marshall D B. Micromechanics of flaw growth in static fatigue: Influence of residual contact stresses. J Amer Cer Soc, 1981, 64: 322–325CrossRefGoogle Scholar
  26. 26.
    Nayebpashaee N, Seyedein S H, Aboutalebi M R, et al. Finite element simulation of residual stress and failure mechanism in plasma sprayed thermal barrier coatings using actual microstructure as the representative volume. Surf Coat Tech, 2016, 291: 103–114CrossRefGoogle Scholar
  27. 27.
    Wei S, Wang F C, Fan Q B, et al. Lifetime prediction of plasmasprayed thermal barrier coating systems. Surf Coat Tech, 2013, 217: 39–45CrossRefGoogle Scholar

Copyright information

© Science China Press and Springer-Verlag GmbH Germany, part of Springer Nature 2018

Authors and Affiliations

  • ShaoLin Li
    • 1
    • 2
  • XiaoGuang Yang
    • 1
    • 2
  • HongYu Qi
    • 1
    • 2
  • Chang Che
    • 3
  1. 1.School of Energy and Power EngineeringBeihang UniversityBeijingChina
  2. 2.Collaborative Innovation Center of Advanced Aero-EngineBeijingChina
  3. 3.School of Materials Science and EngineeringBeihang UniversityBeijingChina

Personalised recommendations