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Residual stress analysis of the thermal barrier coating system by considering the plasma spraying process

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Abstract

The residual stress is the key factor causing the reliability problem of thermal barrier coating (TBC). The failure of plasma spray coatings due to residual stresses is a serious and recurring problem of TBC. The difference of thermal expansion coefficient between the substrate and each coating combined with temperature evolution and temperature gradients during deposition process determine the residual stress for the whole TBC system. The magnitudes and distributions of the residual stresses are affected by deposition process and deposition characteristics. Most of FEA (finite element analysis) has been performed under the assumption that the multilayer coating system is stacked at once without considering the deposition process during plasma spraying. In this research, FEA for a coupled heat transfer and elastic-plastic thermal stress was performed to obtain the more detailed and reliable result of residual stress of the TBC system using the element activation/deactivation technique. The residual stress variation from the start of plasma spraying to cooling stage with room temperature was obtained systematically considering the deposition process. It can be used as reference data to improve the performance of TBC. In addition, the relationship between residual stress and coating conditions such as cooling rate and time is also examined thoroughly.

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Authors and Affiliations

  1. Division of Mechanical Engineering, KAIST, Daejeon, 373-1, Korea

    Myung-Jae Lee & Byung-Chai Lee

  2. SAINT, Sungkyunkwan University, Suwon, 440-746, Korea

    Jang-Gyun Lim & Moon-Ki Kim

  3. School of Mechanical Engineering, Sungkyunkwan University, Suwon, 440-746, Korea

    Moon-Ki Kim

Authors
  1. Myung-Jae Lee
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  2. Byung-Chai Lee
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  3. Jang-Gyun Lim
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  4. Moon-Ki Kim
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Correspondence to Moon-Ki Kim.

Additional information

Recommended by Associate Editor Nam-Su Huh

Myung Jae Lee received his B.S. and M.S. degrees in Mechanical Engineering from Hongik University in 1999 and 2001, respectively. He is currently pursuing the Ph.D. in Computer Aided Structural Analysis & Design(CASAD) lab of Division of Mechanical Engineering in KAIST. His researches focus on the computational structural simulation using FEA in various industrial and research area.

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Lee, MJ., Lee, BC., Lim, JG. et al. Residual stress analysis of the thermal barrier coating system by considering the plasma spraying process. J Mech Sci Technol 28, 2161–2168 (2014). https://doi.org/10.1007/s12206-014-0315-z

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  • DOI: https://doi.org/10.1007/s12206-014-0315-z

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