Stress evaluation of CSZ and SiAlON under Thermo-Mechanical loading condition

Abstract

Abstract This work deals with the Thermo-mechanical analysis of Thermal barrier coating over Aluminum 2026 alloy through Finite Element Method in ANSYS 15.0R software. The coating material is Nano composite (metal matrix). It consists of double ceramic layer (TC1, TC2) with a layer of bond coat (BC) between the substrate (SUB) and the ceramic layers. The top Ceramic layer is of a new kind of refractory material with better oxidation resistant and corrosion resistant above 1000oC. The inside ceramic layer is well known for thermal resistant. In order to give a better bonding strength, the grain size of the coating powder is maintained at Nano scale. A Finite Element model has been developed to identify the intermittent temperature of the coatings under thermal loading conditions. From this FEA result the model was subjected to thermo-mechanical stress analysis to find out the stress distribution over the coatings and the substrate. We analyzed with three different temperatures in the same model. The result shows that the double ceramic layer will reduce the Substrate temperature effectively. The interfacing area and the edges of the coating experience more stresses when compared to other area. The paper reveals that the coated material’s stress concentration is very less when compared to the uncoated material.