Fatigue Behaviour and Life Prediction of YSZ Thermal Barrier Coatings at Elevated Temperature under Cyclic Loads
Abstract
:1. Introduction
2. Specimen Preparation and Experimental Procedure
2.1. Specimen Preparation
2.2. Test Equipment
3. Fatigue Experimental Procedure and Results
3.1. Uniaxial Fatigue Test of Rods
3.2. Uniaxial Fatigue Test of Tubes
3.3. Multiaxial Fatigue Test of Tubes
4. Finite Element Analysis
4.1. Computation Method
4.2. Analysis of Computational Results
5. Proposal of Fatigue Life Model
6. Conclusions
- (1)
- The study revealed that under cyclic stress, the ceramic topcoat on the high-temperature alloy might experience fatigue cracking before the substrate fractures. Specimens that did not fracture were embedded in epoxy resin and sectioned axially. The SEM images of the sectioned specimen revealed that cracks in the ceramic topcoat extended from the topcoat to the interface between the bondcoat and topcoat, but did not penetrate the bondcoat. Additionally, there were no interfacial cracks found in the bondcoat and substrate.
- (2)
- During axial tensile fatigue tests, cracks in the topcoat initially appeared perpendicular to the direction of the load. When subjected to tensile-torsion loads with a 90° phase difference, the cracks on the edges of the radial hole in the tube were oriented at −70° and 110° relative to the edges of the hole. Calculations revealed that the location of the maximum principal stress corresponded to the location of the initial crack, and the direction of the principal stress aligned with the direction of the crack opening.
- (3)
- A fatigue life model was proposed, utilizing the maximum principal stress as the damage parameter, taking into account the stress gradient and the impact of multiaxial loads on fatigue life. This model was used to predict the cracking life of ceramic topcoat thin-walled tubes with radial holes under loads parallel to the coating interface. Excluding two data points where cracking occurred immediately upon loading, the life prediction results fell within a four-fold scatter band, with 77% of the prediction results falling within a two-fold scatter band.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
Abbreviations
APS | Atmospheric Plasma Spraying |
BC | Bondcoat |
EB-PVD | Electron Beam Physical Vapor Deposition |
FEM | Finite Element Method |
HVOF | High-Velocity Oxygen-Fuel |
SEM | Scanning Electron Microscope |
TBCs | Thermal Barrier Coatings |
TC | Topcoat |
YSZ | Yttria Stabilized Zirconia |
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Element | C | Cr | Co | Ni | W | Mo | Al | Ti | Ta | B |
Content (%) | 0.07∼0.12 | 13.5∼14.3 | 9.0∼10.0 | rest | 3.5∼4.1 | 1.3∼1.7 | 2.8∼3.4 | 4.6∼5.2 | 2.5∼3.1 | 0.007∼0.02 |
Element | Si | P | S | Pb | Bi | As | Sn | Sb | ||
Content (%, ≤) | 0.2 | 0.005 | 0.01 | 0.0005 | 0.0001 | 0.005 | 0.002 | 0.001 |
Number | Temperature (°C) | Max Load (kN) | Life of Topcoat (Cycle) |
---|---|---|---|
FAB-800-1040-1 | 800 | 29.41 | 1360 |
FAB-800-1020-1 | 28.84 | 1400 | |
FAB-800-1000-1 | 28.27 | 1600 | |
FAB-800-980-1 | 27.71 | 3600 | |
FAB-800-980-2 | 800 | ||
FAB-800-960-1 | 27.14 | 1700 | |
FAB-800-920-1 | 26.01 | 2100 | |
FAB-800-800-1 | 22.62 | 5600 | |
FAB-870-840-1 | 870 | 23.75 | 900 |
FAB-870-840-2 | 1 | ||
FAB-870-820-1 | 23.18 | 1050 | |
FAB-870-800-1 | 22.62 | 1440 | |
FAB-870-770-1 | 21.77 | 840 | |
FAB-870-770-2 | 2700 | ||
FAB-870-760-1 | 21.49 | 1700 | |
FAB-870-730-1 | 20.64 | 4700 | |
FAB-870-720-1 | 20.36 | 2100 | |
FAB-870-660-1 | 18.66 | 5900 | |
FAB-870-600-1 | 16.97 | 15,000 |
Number | Temperature (°C) | Max Load (kN) | Diameters of Radial Hole (mm) | Life of Topcoat (Cycle) |
---|---|---|---|---|
FAT-800-810-H1-1 | 800 | 22.90 | 1 | 100 |
FAT-800-810-H2-1 | 2 | 1 | ||
FAT-800-630-H1-1 | 17.81 | 1 | 300 | |
FAT-800-630-H2-1 | 2 | 60 | ||
FAT-870-600-H1-1 | 870 | 17.36 | 1 | 270 |
FAT-870-600-H2-1 | 2 | 90 | ||
FAT-870-450-H1-1 | 12.72 | 1 | 1380 | |
FAT-870-450-H2-1 | 2 | 1300 |
Property | Temperature (°C) | Elastic Modulus (GPa) | Poisson’s Ratio | Thermal Expansion Coefficient (10−6K−1) | Density (kg·m−3) | Specific Heat Capacity (J·kg−1·K−1) | |
---|---|---|---|---|---|---|---|
Material | |||||||
YSZ (TC) [26,27] | 20 | 17.5 | 0.2 | blank | 5200 | 437 | |
220 | 16.3 | ||||||
420 | 15.2 | ||||||
620 | 14.0 | ||||||
820 | 12.9 | ||||||
1020 | 11.7 | ||||||
Al2O3 (TGO) [28] | 22 | 386.0 | 0.257 | 6.0 | 3978 | 857 | |
566 | 347.6 | 8.0 | |||||
1149 | 312.1 | 8.9 | |||||
MCrAlY (BC) [28] | 22 | 137.9 | 0.27 | 15.16 | 7320 | 501 | |
566 | 124.0 | 15.37 | |||||
1149 | 93.8 | 17.48 | |||||
DZ411 (sub) [29] | 25 | 129.9 | 0.3 | 11.9 | 8344 | 469 | |
100 | 128.0 | 11.9 | 474 | ||||
200 | 126.0 | 12.4 | 482 | ||||
300 | 123.0 | 12.6 | 491 | ||||
400 | 118.0 | 12.9 | 501 | ||||
500 | 114.0 | 13.2 | 511 | ||||
600 | 110.0 | 13.6 | 522 | ||||
700 | 106.0 | 14.0 | 534 | ||||
800 | 101.0 | 14.5 | 547 | ||||
900 | 95.0 | 15.0 | 561 | ||||
1000 | 86.0 | 15.6 | 575 |
Temperature (°C) | 50 | 100 | 150 | 200 | 250 | 300 | 350 | 400 | 450 | 500 | 550 |
Themal Expansion Coefficient () | 12.16 | 11.81 | 11.41 | 12.08 | 11.88 | 11.53 | 11.66 | 11.68 | 11.66 | 11.66 | 11.66 |
Temperature (°C) | 600 | 650 | 700 | 750 | 800 | 850 | 900 | 950 | 1000 | 1050 | 1100 |
Themal Expansion Coefficient () | 11.43 | 11.51 | 11.46 | 11.41 | 11.41 | 11.33 | 11.28 | 11.21 | 11.18 | 10.96 | 10.66 |
Parameter | A1 | A2 | A3 | A4 |
Value | 4.7926 | −1.1892 | 0.5 | 70.8073 |
Temperature (°C) | Hole Diameter (mm) | Max Load (kN) | Max Stress (MPa) | Stress Ratio | Predicted Life (Cycle) | Test Life (Cycle) |
---|---|---|---|---|---|---|
800 | 1 | 22.90 | 288.44 | 0.201 | 153 | 100 |
800 | 1 | 17.81 | 233.37 | 0.237 | 317 | 300 |
870 | 1 | 17.36 | 240.51 | 0.277 | 297 | 270 |
870 | 1 | 12.72 | 190.16 | 0.338 | 2018 | 1380 |
800 | 2 | 22.90 | 310.61 | 0.169 | 126 | 1 |
800 | 2 | 17.81 | 249.90 | 0.198 | 238 | 60 |
870 | 2 | 17.36 | 255.47 | 0.232 | 230 | 90 |
870 | 2 | 12.72 | 199.63 | 0.283 | 1015 | 1300 |
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Share and Cite
Tao, Q.; Wang, Y.; Zheng, Y. Fatigue Behaviour and Life Prediction of YSZ Thermal Barrier Coatings at Elevated Temperature under Cyclic Loads. Coatings 2024, 14, 960. https://doi.org/10.3390/coatings14080960
Tao Q, Wang Y, Zheng Y. Fatigue Behaviour and Life Prediction of YSZ Thermal Barrier Coatings at Elevated Temperature under Cyclic Loads. Coatings. 2024; 14(8):960. https://doi.org/10.3390/coatings14080960
Chicago/Turabian StyleTao, Qiannan, Yanrong Wang, and Yu Zheng. 2024. "Fatigue Behaviour and Life Prediction of YSZ Thermal Barrier Coatings at Elevated Temperature under Cyclic Loads" Coatings 14, no. 8: 960. https://doi.org/10.3390/coatings14080960