Finite element simulation of residual stress and failure mechanism in plasma sprayed thermal barrier coatings using actual microstructure as the representative volume

Nayebpashaee, Nasim; Seyedein, S.H.; Aboutalebi, M.R.; Sarpoolaky, H.; Hadavi, S.M.M.

doi:10.1016/j.surfcoat.2016.02.028

Cited by 99 publications

(20 citation statements)

References 40 publications

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“…The resulting structure is two-dimensional and can be meshed using tools like OOF (Ref 25). Examples for such simulations are Ref 25,26,27,28. Although such simulations can yield valuable insights into the effect of the microstructure on stresses or crack propagation, quantitatively the resulting stresses differ from the stresses in the full three-dimensional system as shown in the previous section. This effect is especially pronounced if voids are present.…”

Section: Interface Geometrymentioning

confidence: 99%

A Guide to Finite Element Simulations of Thermal Barrier Coatings

Bäker

Seiler

2017

J Therm Spray Tech

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To understand the stress evolution and failure mechanisms of thermal barrier coatings (TBCs), finite element simulations are an invaluable tool. Simulations are especially useful to unwrap complex interactions of different phenomena at high temperature, including creep, sintering, diffusion, and oxidation. However, the correct setup and evaluation of a finite element model for this problem are difficult. This article reviews critical issues in modelling TBC systems. Some of the most important aspects are as follows: (a) stresses in 3D simulations may differ considerably from 2D models; (b) the interface shape strongly affects the stresses and using an idealized geometry may underestimate stresses; (c) crack propagation requires simulating sufficiently large regions to correctly capture stress redistribution; (d) a correct description of the material behaviour (visco-plasticity, TGO growth, sintering) is crucial in determining the stress state. The article discusses these and other issues in detail and provides guidelines on the choice of model parameters, boundary conditions, etc. The paper also points out open questions in modelling TBC systems and discusses aspects of verification and validation.

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Section: Interface Geometrymentioning

confidence: 99%

A Guide to Finite Element Simulations of Thermal Barrier Coatings

Bäker

Seiler

2017

J Therm Spray Tech

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“…At present, crack analysis of SOFC is mainly focused on planar type instead of corrugated type, but there are many analyses about the thermal barrier coating (TBC) with corrugated interface . Because the structure of TBC is similar to that of corrugated SOFC, the analysis method of interfacial crack for corrugated TBC can be used for reference.…”

Section: Introductionmentioning

confidence: 99%

“…Furthermore, the mechanism of crack initiation and degradation for planar SOFC at high working temperature was obtained, and crack initiation in the anode-electrolyte interface was concluded by Kim et al 20 At present, crack analysis of SOFC is mainly focused on planar type instead of corrugated type, but there are many analyses about the thermal barrier coating (TBC) with corrugated interface. [21][22][23][24][25][26][27][28] Because the structure of TBC is similar to that of corrugated SOFC, the analysis method of interfacial crack for corrugated TBC can be used for reference. In addition, the research on corrugated SOFC mainly concentrates on its electrochemical performance, 9,10,[29][30][31] and the corresponding mechanical analysis is rare.…”

Section: Introductionmentioning

confidence: 99%

Crack propagation of planar and corrugated solid oxide fuel cells during cooling process

2019

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Summary The corrugated solid oxide fuel cell (SOFC) can effectively improve energy density and transformation efficiency compared with conventional planar SOFC, but its stability and durability have not been systematically analyzed. The residual stress of SOFC may lead to crack initiation and propagation during cooling process, so stress distributions of planar and corrugated SOFCs are simulated to analyze the location of crack initiation. The materials of electrolyte, anode, and cathode in this paper are yttria‐stabilization zirconia (YSZ), Ni‐YSZ, and strontium‐doped lanthanum manganite (LSM), respectively. The result shows that the edge of cell is more prone to cracking. Therefore, precracks including edge crack and middle crack are introduced into anode‐electrolyte interfaces to investigate crack propagation of two types of SOFCs during cooling process. For corrugated SOFC, the cracks propagate more slowly, and the cell is less prone to interfacial delamination compared with planar SOFC. In addition, the interface energy release rates are obtained to further analyze crack propagation of two types of SOFCs, and the corrugated SOFC has lower energy release rate. The research in this paper provides guidance for stability analysis and lays a foundation for future mechanical analysis of corrugated SOFC.

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“…What's more, they simplified the formulas by assuming a uniform distribution of stress in the coatings, contradicting with the practice results of stress distribution. In addition, finite element simulation has also been used to predict residual stresses in thermal barrier coatings …”

Section: Introductionmentioning

confidence: 99%

Residual thermal stresses prediction for CVD coating/substrate system based on a numerical model

Wang

Chen

Pan

et al. 2018

Int J Applied Ceramic Tech

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For a chemical vapor deposition (CVD) coating/substrate system, an improved and optimized numerical model is established to predict the residual thermal stresses. This model takes into account both the normal and bending strains and is developed based on the concept of a misfit strain between coating and substrate. Comparisons are presented between predictions from this model and from finite element analysis. The effects of coating thickness, elastic modulus, temperature difference, and multiple deposition on the residual stresses in the coating/substrate system have also been analyzed in detail. Furthermore, some confirmatory CVD SiC experiments with different layers have also been conducted according to the analysis model. The predictions that the multiple deposition system can relieve the residual thermal stresses and reduce the microcracks in the outermost coating effectively, are consistent with the numerical model.

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Finite element simulation of residual stress and failure mechanism in plasma sprayed thermal barrier coatings using actual microstructure as the representative volume

Cited by 99 publications

References 40 publications

A Guide to Finite Element Simulations of Thermal Barrier Coatings

A Guide to Finite Element Simulations of Thermal Barrier Coatings

Crack propagation of planar and corrugated solid oxide fuel cells during cooling process

Residual thermal stresses prediction for CVD coating/substrate system based on a numerical model

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