Time -dependent behavior and thermal fracture in functionally graded thermal barrier coatings
Abstract
The objective of this research was to characterize the thermo-mechanical response and fracture behavior of zirconia-bond coat (BC) alloy functionally graded thermal barrier coatings (TBCs) under high heat flux thermal loads. Under the resulting high surface temperatures and gradients, the coatings develop surface cracks as well as TBC-BC interface cracks. Time-dependent (viscoplastic) deformations in the TBC layers were the major cause for surface and interface fracture. Micromechanics models were developed to estimate the effective thermo-elastic properties and time-dependent response of YSZ-BC alloy particulate composites that constitute the layers of a graded TBC. These effective properties were then utilized in numerical fracture mechanics analyses to study the influence of coating architecture on its fracture response. The driving force for surface crack initiation and for the formation of multiple surface cracks was found to increase with compositional gradation. It was also found that replacing a single-layer (non-graded) TBC by a functionally graded TBC of comparable thermal resistance resulted in a reduced driving force for interface crack growth. The formation of multiple surface cracks and its higher flexural stiffness were found to impart a graded TBC with a higher resistance to interface fracture. Methodologies were developed to estimate the fracture resistance and toughness of graded TBCs. It was found that both the single-layer zirconia TBC as well as functionally graded TBCs showed an increase in fracture resistance with crack advance. The addition of BC alloy was found to enhance the fracture toughness of the layers in a graded TBC. However, the magnitude of toughness enhancement seen was not very significant. Laser thermal shock experiments were conducted on plasma sprayed single-layer zirconia-BC alloy composite coatings. Coatings with three different compositions, of similar thermal resistance were considered. It was found that coatings with a higher BC alloy content experienced more severe surface and interface thermal fracture. These findings were explained by considering the effective time-dependent response and fracture toughness of these composites. Finally, the possibility of inhibiting the time-dependent effects and reducing the driving force for interface crack growth in zirconia based TBC systems, through the addition of mullite was considered.
Degree
Ph.D.
Advisors
Kokini, Purdue University.
Subject Area
Mechanical engineering|Aerospace materials|Materials science
Off-Campus Purdue Users:
To access this dissertation, please log in to our
proxy server.