Finite element simulation of a coating formation on a turbine blade during plasma spraying

Lugscheider, E.; Nickel, R.

doi:10.1016/s0257-8972(03)00331-1

Cited by 17 publications

(16 citation statements)

References 4 publications

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“…The coating formation is realized by applying a finite element activation algorithm. [44,46,47] The PYSZ-TBC coating elements are deactivated before the simulation of the coating formation is carried out. The TBC elements are activated to represent the coating formation in the current time increment of the simulation during the simulation period.…”

Section: Coating Formation Simulationmentioning

confidence: 99%

“…25). [46] Free boundaries at the surface of the calculation domain represent the plasma free jet behaviour in the infinity of the ambient medium. The boundary condition at the plasma jet inlet is defined by the calculated field parameters at the noz- zle exit of the plasma torch simulation.…”

Section: Plasma Free Jet Simulationmentioning

confidence: 99%

“…Furthermore the particles are heated, melted and partially evaporated in the plasma jet due to the heat transfer from the hot plasma jet to the powder particles. [41,46,50] The equations of motion with the acting (drag) force on the right hand side of the equation have to be solved to calculate the particle trajectories in the plasma jet. Additionally, the heat conduction equation with a heat transfer at the surface of the spherical particles has to be solved to determine the temperature behaviour of the particles with phenomena like melting and evaporation.…”

Section: Powder Particles Characteristicsmentioning

confidence: 99%

“…Additionally, the heat conduction equation with a heat transfer at the surface of the spherical particles has to be solved to determine the temperature behaviour of the particles with phenomena like melting and evaporation. [46] In Figure 28, the front view of powder particles of different ceramic materials is shown. [46] Two different ways are chosen for the simulation of the powder particle characteristics in the project.…”

Section: Powder Particles Characteristicsmentioning

confidence: 99%

“…[46] In Figure 28, the front view of powder particles of different ceramic materials is shown. [46] Two different ways are chosen for the simulation of the powder particle characteristics in the project. One way was the coupling between plasma free jet and powder particles simulation was by an in-house program, the PLASMA2000 program.…”

Section: Powder Particles Characteristicsmentioning

confidence: 99%

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Integrated Approach for the Development of Advanced, Coated Gas Turbine Blades

et al. 2006

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This paper describes a through‐process modelling on a microstructural level of the production of a coated turbine blade, including its in‐service properties and degradation, accompanied by the actual production and testing of a CMSX‐4 single crystal turbine blade dummy. The following steps are dealt with by modelling and experiment: solidification of the blade alloy during casting, microstructural changes during homogenization and aging heat treatments, chemical vapour deposition of an Al2O3 diffusion barrier coating, physical vapour deposition (sputtering) of a (Ni,Co)CrAlY bond coat, atmospheric plasma spraying of an Y2O3 stabilized ZrO2 thermal barrier coating and microstructural changes and development of critical stresses at in‐service conditions. This work forms a part of the Collaborative Research Centre 370 (SFB 370) “Integrative materials modelling”.

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Section: Coating Formation Simulationmentioning

confidence: 99%

Section: Plasma Free Jet Simulationmentioning

confidence: 99%

Section: Powder Particles Characteristicsmentioning

confidence: 99%

Section: Powder Particles Characteristicsmentioning

confidence: 99%

Section: Powder Particles Characteristicsmentioning

confidence: 99%

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Integrated Approach for the Development of Advanced, Coated Gas Turbine Blades

et al. 2006

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Advanced Homogenization Strategies in Material Modeling of Thermally Sprayed TBCs

Bobzin¹,

Lugscheider²,

Nickel³

et al. 2006

Adv Eng Mater

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Partially yttria stabilized zirconia (PYSZ) thermal barrier coatings (TBCs) are applied in aircraft engines and gas turbines. Especially PYSZ coatings on turbine blades fulfill a heat and corrosion functionality during the operational use of the gas turbines. The PYSZ-layers lead to an increase of the life time of the turbine blades due to a decrease of the thermal and mechanical loading of the Ni-alloy components during gas turbine operation. For this reason, PYSZ-TBCs can also limit the costs of the turbine engine's maintenance.There are different technological methods to produce PYSZ thermal barrier coatings. The most applied methods in practice are the thermal spraying technologies, especially atmospheric plasma spraying (APS), and electron beam physical vapour deposition (EB-PVD).The chosen process technology and the set of process parameters directly affect the microstructure of the PYSZ-TBC. The coatings show a specific physical behavior in combination with the Ni-base alloy blade due to this specific microstructure. It is known, that APS PYSZ-TBCs have a lower thermal conductivity than EB-PVD-PYSZ-TBCs. Therefore, the thermal insulation of the first coatings is better than of the second ones. But the lateral strain tolerance of EB-PVD coatings is higher due to the columnar structure. This makes the EB-PVD-coatings more resistant against thermal cycling loading.But if a specific process is looked at, then the microstructure of the PYSZ-TBCs can be influenced highly by the process control, the adjustable process parameters. This can be investigated by experimental studies. Process simulations have been becoming an alternative technique since years and the quality of simulation results increases with the quality of the developed simulation models and the hardware capacities. The PYSZ-TBC microstructure influences the physical behaviour of the coating/component compound in the mesoand macroscale consideration. Modelling and simulation methods can also be applied here as a complement or an alternative to experimental measurements to determine the correlation between the microstructure and the meso-and macroscale physical coating behaviour.This article focuses on the application of advanced homogenization strategies in the material properties and laws estimation for thermally sprayed (APS) PYSZ-TBCs.Thermally sprayed thermal barrier coatings made of partially yttria stabilized zirconia show a characteristic microstructure. SEM-images of polished samples illustrate the porous, lamellar and micro-cracked structure ( Fig. 1(a)). These SEM-images are used as basis for the application of homogenization methods. This is an example for the combination of experimental and simulation methods. Alternatively, the microstructure can be obtained by a full APS process simulation. This can be realized in future, if the gaps in the coating formation simulation modeling (e.g. contact phenomena, crack formation and progression) are closed.Investigation of microstructure by spectral analysis: The SEMimages of polished APS-PYSZ-TB...

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Modeling of Coating Process, Phase Changes, and Damage of Plasma Sprayed Thermal Barrier Coatings on Ni‐Base Superalloys

et al. 2010

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The paper gives an overview on the modeling activities on plasma sprayed thermal barrier coating in the frame of TFB 63. In the first part, through‐process modeling of the APS deposition of a ZrO2 based TBC is described. Starting from simulation of the plasma jet, heat transfer into the powder particles, particle melting, particle impact on the substrate surface, and solidification is simulated. A homogenization method is introduced to describe the mechanical properties of the resulting TBC. The second part shows simulation of interdiffusion and phase transformations of MCrAlY and intermetallic oxidation protection coatings on several cast Ni‐base alloy substrates. Finally, FEM‐based damage simulation of oxidation protection coatings by transversal fatigue cracks during thermomechanical fatigue loading as well as by delamination of the TBC during thermocyclic loading is discussed.

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Finite element simulation of a coating formation on a turbine blade during plasma spraying

Cited by 17 publications

References 4 publications

Integrated Approach for the Development of Advanced, Coated Gas Turbine Blades

Integrated Approach for the Development of Advanced, Coated Gas Turbine Blades

Advanced Homogenization Strategies in Material Modeling of Thermally Sprayed TBCs

Modeling of Coating Process, Phase Changes, and Damage of Plasma Sprayed Thermal Barrier Coatings on Ni‐Base Superalloys

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