Effect of Residual Stresses and Prediction of Possible Failure Mechanisms on Thermal Barrier Coating System by Finite Element Method

This work is focused on the effect of the residual stresses resulting from the coating process and thermal cycling on the failure mechanisms within the thermal barrier coating (TBC) system. To reach this objective, we studied the effect of the substrate preheating and cooling rate on the coating pro...

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Bibliographic Details
Published in:Journal of thermal spray technology 2010-09, Vol.19 (5), p.1054-1061
Main Authors: Ranjbar-Far, M., Absi, J., Mariaux, G., Shahidi, S.
Format: Article
Language:English
Subjects:
Analytical Chemistry
Applied sciences
Characterization and Evaluation of Materials
Chemistry and Materials Science
Coating
Cooling
Corrosion and Coatings
Engineering Sciences
Exact sciences and technology
Failure mechanisms
Finite element method
Low temperature
Machines
Manufacturing
Materials
Materials Science
Mathematical analysis
Mathematical models
Metals. Metallurgy
Nonmetallic coatings
Peer Reviewed
Processes
Production techniques
Residual stress
Stresses
Surface treatment
Surfaces and Interfaces
Temperature distribution
Thermal barrier coatings
Thin Films
Tribology
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Summary:This work is focused on the effect of the residual stresses resulting from the coating process and thermal cycling on the failure mechanisms within the thermal barrier coating (TBC) system. To reach this objective, we studied the effect of the substrate preheating and cooling rate on the coating process conditions. A new thermomechanical finite element model (FEM) considering a nonhomogeneous temperature distribution has been developed. In the results, we observed a critical stress corresponding to a low substrate temperature and high cooling rate during spraying of the top-coat material. Moreover, the analysis of the stress distribution after service shows that more critical stresses are obtained in the case where residual stresses are taken into account.
ISSN:1059-9630
1544-1016
DOI:10.1007/s11666-010-9512-1