等离子喷涂8YSZ热障涂层隔热效果及内应力演变有限元模拟
Finite Element Simulation of Thermal Insulation Effect and Internal Stress Evolution of Plasma Sprayed 8YSZ Thermal Barrier Coating
摘 要
采用等离子喷涂法制备质量分数8%氧化钇稳定氧化锆（8YSZ）热障涂层，并进行隔热和热震循环试验；构建简易有限元模型对热障涂层的隔热性能和热震循环中的内应力演变进行模拟，并对破坏机理进行分析。结果表明：模拟得到热障涂层的隔热温度在167.60～262.22℃，隔热效果良好，与试验结果的相对误差在10%以内；热障涂层的隔热效果随厚度增加而增强；热震循环产生的应力在涂层的界面边缘处集中，与试验得到的在涂层边缘处出现裂纹和脱落并逐渐延伸至中心的失效方式相吻合；随涂层厚度增加，热震循环升温和降温后的应力增大。
有限元模拟
隔热效果
热震循环
应力分布
thermal barrier coating
finite element simulation
thermal insulation effect
thermal shock cycle
stress distribution
Abstract
The 8wt% yttrium stabilized zirconia (8YSZ) thermal barrier coating was prepared by plasma spraying, and the thermal insulation and thermal shock cycle tests were carried out. A simple finite element model was constructed to simulate the thermal insulation performance and the internal stress evolution in thermal shock cycle, and the failure mechanism was analyzed. The results show that the thermal insulation temperature of the barrier coating by simulation was 167.60-262.22℃, indicating the thermal insulation effect was good, and the relative error between the simulation and the test result was less than 10%. The thermal insulation effect increased with increasing thickness. The stress generated by thermal shock cycles was concentrated at the edge of the coating interface, which was consistent with the failure mode obtained by experiments that cracks and fall off appeared at the coating edge and expanded to the core. With increasing thickness of the coating, the stress after heating and cooling of the thermal shock cycle increased.
中图分类号 U668.3 DOI 10.11973/jxgccl202309016
所属栏目 专题报道（金属材料表面处理）
基金项目 工业和信息化部2018年绿色制造系统集成计划批准项目
收稿日期 2022/11/15
修改稿日期 2023/7/17
网络出版日期
作者单位点击查看
备注吴硕(1984-),男,山东青岛人,副教授,博士
引用该论文: WU Shuo,ZHAO Yuantao,WANG Liang,LI Wenge,LIU Weilai,ZHANG Shitao,WU Yanpeng,MA Rong. Finite Element Simulation of Thermal Insulation Effect and Internal Stress Evolution of Plasma Sprayed 8YSZ Thermal Barrier Coating[J]. Materials for mechancial engineering, 2023, 47(9): 94～100
吴硕,赵远涛,王亮,李文戈,刘未来,张士陶,吴艳鹏,马融. 等离子喷涂8YSZ热障涂层隔热效果及内应力演变有限元模拟[J]. 机械工程材料, 2023, 47(9): 94～100
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【2】CLARKE D R, OECHSNER M, PADTURE N P.Thermal-barrier coatings for more efficient gas-turbine engines[J].MRS Bulletin, 2012, 37(10):891-898.
【3】BAKAN E, VAßEN R.Ceramic top coats of plasma-sprayed thermal barrier coatings:Materials, processes, and properties[J].Journal of Thermal Spray Technology, 2017, 26(6):992-1010.
【4】LIU Z Y, ZHU W, YANG L, et al.Numerical prediction of thermal insulation performance and stress distribution of thermal barrier coatings coated on a turbine vane[J].International Journal of Thermal Sciences, 2020, 158:106552.
【5】FEI C G, QIAN Z Q, REN J E, et al.Numerical and experimental research on thermal insulation performance of marine diesel engine piston based on YSZ thermal barrier coating[J].Coatings, 2021, 11(7):765.
【6】ABDELGAWAD A, AL-ATHEL K.Effect of TGO thickness, pores, and creep on the developed residual stresses in thermal barrier coatings under cyclic loading using SEM image-based finite element model[J].Ceramics International, 2021, 47(14):20064-20076.
【7】WANG L, MING C, ZHONG X H, et al.Prediction of critical rupture of plasma-sprayed yttria stabilized zirconia thermal barrier coatings under burner rig test via finite element simulation and in situ acoustic emission technique[J].Surface and Coatings Technology, 2019, 367:58-74.
【8】HAN M, HUANG J H, CHEN S H.A parametric study of the double-ceramic-layer thermal barrier coating part II:Optimization selection of mechanical parameters of the inside ceramic layer based on the effect on the stress distribution[J].Surface and Coatings Technology, 2014, 238:93-117.
【9】WANG L, WANG Y, SUN X G, et al.Finite element simulation of residual stress of double-ceramic-layer La2Zr2O7/8YSZ thermal barrier coatings using birth and death element technique[J].Computational Materials Science, 2012, 53(1):117-127.
【10】WANG L, WANG Y, ZHANG W Q, et al.Finite element simulation of stress distribution and development in 8YSZ and double-ceramic-layer La2Zr2O7/8YSZ thermal barrier coatings during thermal shock[J].Applied Surface Science, 2012, 258(8):3540-3551.
【11】WANG L, YANG J S, NI J X, et al.Influence of cracks in APS-TBCs on stress around TGO during thermal cycling:A numerical simulation study[J].Surface and Coatings Technology, 2016, 285:98-112.
【12】郑允宅, 朱建峰, 曹萍丽, 等.等离子喷涂热障涂层中应力分布的有限元模拟[J].机械工程材料, 2015, 39(9):84-88. ZHENG Y Z, ZHU J F, CAO P L, et al.Finite element simulation of stress distribution in plasma sprayed thermal barrier coating[J].Materials for Mechanical Engineering, 2015, 39(9):84-88.
【13】WANG L, ZHONG X H, ZHAO Y X, et al.Design and optimization of coating structure for the thermal barrier coatings fabricated by atmospheric plasma spraying via finite element method[J].Journal of Asian Ceramic Societies, 2014, 2(2):102-116.
【14】易德先, 胡芳友, 胡滨, 等.激光熔覆K418高温合金温度场的数值模拟[J].应用激光, 2009, 29(5):419-422. YI D X, HU F Y, HU B, et al.Numerical simulation of laser cladding temperature field of K418 superalloy[J].Applied Laser, 2009, 29(5):419-422.
【15】周正华, 杨帆, 屠挺生, 等.K418高温合金下引式热型连铸温度场模拟[J].上海金属, 2019, 41(3):89-95. ZHOU Z H, YANG F, TU T S, et al.Simulation of temperature field in K418 superalloy during downward Ohno continuous casting process[J].Shanghai Metals, 2019, 41(3):89-95.
【16】ZHOU C G, WANG N, XU H B.Comparison of thermal cycling behavior of plasma-sprayed nanostructured and traditional thermal barrier coatings[J].Materials Science and Engineering:A, 2007, 452/453:569-574.
【17】WANG X, LEE G, ATKINSON A.Investigation of TBCs on turbine blades by photoluminescence piezospectroscopy[J].Acta Materialia, 2009, 57(1):182-195.
【18】HU Z C, LIU B, WANG L A, et al.Research progress of failure mechanism of thermal barrier coatings at high temperature via finite element method[J].Coatings, 2020, 10(8):732.
【19】WANG Y, LIU Q, ZHENG Q S, et al.Bonding and thermal-mechanical property of gradient NiCoCrAlY/YSZ thermal barrier coatings with millimeter level thickness[J].Coatings, 2021, 11(5):600.
【20】MEHBOOB G, LIU M J, XU T, et al.A review on failure mechanism of thermal barrier coatings and strategies to extend their lifetime[J].Ceramics International, 2020, 46(7):8497-8521.
【21】PADTURE N P, GELL M, JORDAN E H.Thermal barrier coatings for gas-turbine engine applications[J].Science, 2002, 296(5566):280-284.
【22】LEE M J, LEE B C, LIM J G, et al.Residual stress analysis of the thermal barrier coating system by considering the plasma spraying process[J].Journal of Mechanical Science and Technology, 2014, 28(6):2161-2168.
【23】PAWLOWSKI L.The science and engineering of thermal spray coatings[M].Hoboken:John Wiley & Sons, 2008.
【24】ABDUL-AZIZ A.Durability modeling review of thermal- and environmental-barrier-coated fiber-reinforced ceramic matrix composites part I[J].Materials, 2018, 11(7):1251.
【25】王进双.氧化锆热障涂层失效机理研究[D].武汉:武汉理工大学, 2018. WANG J S.Failure mechanism of zirconia thermal barrier coating[D].Wuhan:Wuhan University of Technology, 2018.
【26】KUMAR V, BALASUBRAMANIAN K.Progress update on failure mechanisms of advanced thermal barrier coatings:A review[J].Progress in Organic Coatings, 2016, 90:54-82.
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