Dynamic-stiffening-induced aggravated cracking behavior driven by metal-substrate-constraint in a coating/substrate system

doi:10.1016/j.jmst.2020.04.076

Abstract

Abstract:

Air plasma sprayed thermal barrier coatings (APS-TBCs) saw their wide application in high-temperature-related cutting-edge fields. The lamellar structure of APS-TBCs provides a significant advantage on thermal insulation. However, short life span is a major headache for APS-TBCs. This is highly related to the property changes and passive behaviors of the coatings during thermal service. Herein, a finite element model was developed to investigate the dynamic stiffening and substrate constraint on total spallation process. Results show that the stiffening accelerates the crack propagation of APS-TBCs. The driving force for crack propagation, which is characterized by strain energy release rate (SERR), is significantly enlarged. Consequently, the crack starts to propagate when the SERR exceeds the fracture toughness. In addition, the changing trends of SERR and crack propagation features are highly associated with temperatures. A higher temperature corresponds to more significant effect of stiffening on substrate constraint. In brief, temperature-dependent stiffening significantly aggravates the substrate constraint effect on APS-TBCs, which is one of the major causes for the spallation. Given that, lowering stiffening degree is essential to maintain high strain tolerance, and to further extend the life span of APS-TBCs. This understanding contributes to the development of advanced TBCs in future applications.

Key words: Thermal barrier coatings, Substrate constraint, Stiffening, Crack propagation, Structural design

Guangrong Li, Chunhua Tang, Guanjun Yang. Dynamic-stiffening-induced aggravated cracking behavior driven by metal-substrate-constraint in a coating/substrate system[J]. J. Mater. Sci. Technol., 2021, 65: 154-163.

Figures/Tables 13

Fig. 1. Development of the model based on experimental observation [13]: (a) global cross-sectional view of a TBC, (b) detailed view of the TC, (c) schematic of the model with inserted micro-pores, and (d) periodic pattern.

Fig. 2. Meshing and boundary conditions in ABAQUS: (a) the periodic pattern, (b) overall meshing and boundary constraints, (c) refined meshes near the crack propagation path.

Table 1 Temperature-dependent material parameters of each layer [46,47,50].

Layers	T (°C)	E (GPa)	ν	α×10^-6 (°C^-1)
TC	25	-	0.2	9.68
	200	-	0.2	-
	400	-	0.2	9.70
	800	-	0.2	-
	1000	-	0.2	11.0
BC	25	218	0.3	10.3
	200	209	0.3	11.3
	400	199	0.3	12.5
	800	162	0.3	13.3
	1000	118	0.3	14.0
SUB	25	210	0.3	12.0
	200	200	0.3	12.6
	400	187	0.3	13.1
	800	156	0.3	13.6
	1000	138	0.3	14.0

Fig. 3. Thermal cycling history for the TBC model.

Fig. 4. Schematic of the VCCT-controlled crack propagation in TC layer [46].

Fig. 5. Evolution of stress state of the model upon temperature cycling: (a) shear stress (S12), and (b) normal stress (S22).

Fig. 6. Dynamic changes of SERR as a function of thermal cycles: (a) GI for the LS case, (b) GII for the LS case, (c) GI for the HS case, (d) GII for the HS case.

Fig. 7. Changes of SERR after cooling to room temperature.

Fig. 8. Changes of SERR from initial state to start of crack propagation.

Fig. 9. Evolution of stress state during crack propagation: (a) shear stress (S12), and (b) normal stress (S22).

Fig. 10. Comparison of visualized crack length upon different stiffening degrees: (a) the case of LS, and (b) the case of HS.

Fig. 11. Relationship between thermal cycles and normalized cracking length.

Fig. 12. Schematic diagram showing the aggravated effect of stiffening on cracking behavior of TBCs driven by substrate constraint.

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