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SCIENCE CHINA Technological Sciences, Volume 61 , Issue 12 : 1882-1888(2018) https://doi.org/10.1007/s11431-018-9333-y

Experimental study and numerical modeling of the damage evolution of thermal barrier coating systems under tension

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  • ReceivedMay 1, 2018
  • AcceptedJul 30, 2018
  • PublishedSep 28, 2018

Abstract

This study investigated the damage evolution (i.e., formation of vertical cracks, transformation of vertical cracks to interfacial crack and delamination) of thermal barrier coating systems under tension by using experimental and numerical methods. Experimental results revealed that the first transverse crack that was perpendicular to the load direction occurred when the strain of the top coat reached 0.5%. The full-scale strain of the top coat layer obtained by using the Digital Image Correlation technique indicated that surface cracks formed due to the coalescence of micro-cracks. Moreover, the results of the finite element method demonstrated that the vertical cracks initiated from the coating surface and extended through the thickness of the coatings. The density of the surface cracks was used as a damage evolution indicator such that numerical simulation could predict the cracking behaviour under tension loading. The results were consistent with those of the experimental study.


Funded by

the National Natural Science Foundation of China(Grant,No.,51571010)

the National Basic Research Program of China(Grant,No.,2015CB057400)


Acknowledgment

This work was supported by the National Natural Science Foundation of China (Grant No. 51571010) and the National Basic Research Program of China (Grant No. 2015CB057400).


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  • Figure 1

    (Color online) (a) Plate sample with TBCs for the tensile tests; (b) schematic illustration of plate sample and (c) experimental arrangement.

  • Figure 2

    (Color online) Finite element meshes for simulating the tension experiment.

  • Figure 3

    (Color online) The traction-separation law of cohesive elements.

  • Figure 4

    (Color online) Stress-strain curves of the TBCs and the substrate samples.

  • Figure 5

    (Color online) DIC results on surface view of the coated sample at different stage of experiment in Figure 4. (a) Point A, 12.21 MPa; (b) point B, 141.56 MPa; (c) point C, 182.10 MPa; (d) point D, 379.75 MPa; (e) point E, 519.31 MPa; (f) point F, 546.49 MPa.

  • Figure 6

    Schematic illustration of the formation mechanism of coating cracks. (a) Phase I; (b) phase II; (c) phase III.

  • Figure 7

    (Color online) SEM micrographs of the longitudinal section at (a) the middle of TBCs sample, and (b) the edge of the TC layer.

  • Figure 8

    (Color online) The cohesive elements damage distribution of the coating sample when the surface cracking began to appear.

  • Figure 9

    (Color online) The stress distribution of the coating during the tension deformation process. (a) 28 steps, the TC began cracking; (b) 49 steps, the vertical crack extends from the coating surface toward the BC and substrate interface, the type I crack appears; (c) the vertical crack reaches the BC and substrate interface; (d) 115 steps, interfacial delamination, i.e. type II crack is observed.

  • Figure 10

    (Color online) The transverse crack number within the parallel section of the loaded sample as a function of tensile strain of substrate.

  • Table 1   Nominal chemical compositions of the bond coat (wt%)

    C

    O

    Cr

    Al

    Y

    Co

    Ni

    <0.7

    0.95

    14~16

    4~6

    1.5~2.0

    5~6

    Bal

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