Reliability Evaluation of EB-PVD Thermal Barrier Coatings in High-Speed Rotation and Gas Thermal Shock

Author:

Yan Weiliang12,Li Cong12ORCID,Liu Zhiyuan123,Cheng Chunyu12,Yang Li12

Affiliation:

1. School of Advanced Materials and Nanotechnology, Xidian University, Xi’an 710126, China

2. Shaanxi Key Laboratory of High-Orbits-Electron Materials and Protection Technology for Aerospace, Xidian University, Xi’an 710126, China

3. Hunan Provincial Key Laboratory of Interface Science/Materials Surface & Technology, School of Materials Science & Engineering, Central South University of Forestry & Technology, Changsha 410004, China

Abstract

The uncertain service life of thermal barrier coatings (TBCs) imposes constraints on their secure application. In addressing this uncertainty, this study employs the Monte Carlo simulation method for reliability evaluation, quantifying the risk of TBC peeling. For reliability evaluation, the failure mode needs to be studied to determine failure criteria. The failure mode of high-speed rotating TBCs under gas thermal shock was studied by combining fluid dynamics simulations and experiments. Based on the main failure mode, the corresponding failure criterion was established using the energy release rate, and its limit state equation was derived. After considering the dispersion of parameters, the reliability of TBCs was quantitatively evaluated using failure probability and sensitivity analysis methods. The results show that the main mode is the fracture of the ceramic layer itself, exhibiting a distinctive top-down “step-like” thinning and peeling morphology. The centrifugal force emerges as the main driving force for this failure mode. The failure probability value on the top side of the blade is higher, signifying that coating failure is more likely at this location, aligning with the experimental findings. The key parameters influencing the reliability of TBCs are rotation speed, temperature, and the thermal expansion coefficient. This study offers a valuable strategy for the secure and reliable application of TBCs on aeroengine turbine blades.

Funder

National Natural Science Foundation of China

National Science and Technology Major Project

Fundamental Research Funds for the Central Universities and the Innovation Fund of Xidian University

Publisher

MDPI AG

Subject

Materials Chemistry,Surfaces, Coatings and Films,Surfaces and Interfaces

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