Abstract
Thermal barrier coatings (TBCs) represent a relatively thin layer of ceramic with the favourable insulating properties, which are generally used to improve the temperature stability of the engineering component such as turbine blades. One of the prime prerequisites of TBCs is to determine the optimised coating configuration with the desired thermo-mechanical properties and enhanced service life. In a typical functionally graded coating structure, this could be achieved by having a trade-off between the thermal insulation and fatigue toughness offered by ceramic in top coat and metal towards the substrate, respectively. In this work, a computational method was used to analyse and optimise the parameters pertaining to thermo-mechanical evaluation of the slurry spray-coated (SST) mullite–nickel ASTM 1018 steel. The composite material properties have been predicted using the classical mean-field micromechanics model and rule of mixtures and the finite element simulation package ANSYS. Experimental validation has been performed to analyse the relative thermal and structural properties of the composite layers of the coatings using transient plane source (TSP)-based thermal constants analyser. The predicted and experimental results were further analysed and optimised for various process parameters using response surface optimisation and multi-objective genetic algorithm, which evaluated the optimum results considering the boundary conditions with a temperature reduction of nearly 306 °C. Further, the research results indicate that suitable thickness of the coating configuration of the slurry-sprayed mullite–nickel TBC system included coating thickness of 57.2 μm, 147.1 μm, and 143.9 μm for bond, intermediate, and top coats, respectively. The material properties were found dependent on the coating composition across the FG structure, and the predicted, computed, and experimental results were in reasonable agreement.
Similar content being viewed by others
References
Ramaswamy, P.; Shankar, V.; Reghu, V.R.; Mathew, N.; Manoj Kumar, S.: A model to predict the influence of inconsistencies in thermal barrier coating (TBC) thicknesses in pistons of IC engines. Mater. Today Proc. 5, 12623–12631 (2018). https://doi.org/10.1016/j.matpr.2018.02.245
Pasupuleti, K.T.; Dsouza, S.; Thejaraju, R.; Venkataraman, S.; Ramaswamy, P.; Murty, N.: Performance and steady state heat transfer analysis of functionally graded thermal barrier coatings systems. Mater. Today Proc. 5, 27936–27945 (2018). https://doi.org/10.1016/j.matpr.2018.10.033
Nguyen, P.; Harding, S.; Ho, S.-Y.: Experimental studies on slurry based thermal barrier coatings. In: 5th Australasian Congress on Applied Mechanics (ACAM 2007), pp. 545–550. Engineers Australia (2007)
Tejero-Martin, D.; Rad, M.R.; McDonald, A.; Hussain, T.: Beyond traditional coatings: a review on thermal-sprayed functional and smart coatings. J. Therm. Spray Technol. 28(4), 598–644 (2019). https://doi.org/10.1007/s11666-019-00857-1
Zhou, D.; Guillon, O.; Vaßen, R.: Development of YSZ thermal barrier coatings using axial suspension plasma spraying. Coatings 7, 120 (2017). https://doi.org/10.3390/coatings7080120
Verma, R.; Kant, S.; Suri, N.M.: Adhesion strength optimization of slurry sprayed mullite-based coating using Taguchi method. Proc. Inst. Mech. Eng. Part. E J. Process. Mech. Eng. 230, 87–96 (2014). https://doi.org/10.1177/0954408915595948
Verma, R.; Suri, N.M.; Kant, S.: Parametric appraisal of slurry-sprayed mullite coatings for coating thickness. J. Therm. Spray Technol. (2016). https://doi.org/10.1007/s11666-016-0437-1
Verma, R.; Suri, N.M.; Kant, S.: Effect of parameters on adhesion strength for slurry spray coating technique. Mater. Manuf. Process. (2017). https://doi.org/10.1080/10426914.2016.1221090
Kokini, K.; Takeuchi, Y.R.; Choules, B.D.: Surface thermal cracking of thermal barrier coatings owing to stress relaxation: zirconia vs mullite. Surf Coat. Technol. 82, 77–82 (1996). https://doi.org/10.1016/0257-8972(95)02647-9
Torrecillas, R.; Calderón, J.M.; Moya, J.S.; Reece, M.J.; Davies, C.K.L.; Olagnon, C.; Fantozzi, G.: Suitability of mullite for high temperature applications. J. Eur. Ceram. Soc. 19, 2519–2527 (2002). https://doi.org/10.1016/s0955-2219(99)00116-8
Gilbert, A.; Kokini, K.; Sankarasubramanian, S.: Thermal fracture of zirconia–mullite composite thermal barrier coatings under thermal shock: an experimental study. Surf Coat. Technol. 202, 2152–2161 (2007). https://doi.org/10.1016/j.surfcoat.2007.09.001
Wang, L.; Zhong, X.H.; Zhao, Y.X.; Yang, J.S.; Tao, S.Y.; Zhang, W.; Wang, Y.; Sun, X.G.: Effect of interface on the thermal conductivity of thermal barrier coatings: a numerical simulation study. Int. J. Heat Mass Transf. 79, 954–967 (2014). https://doi.org/10.1016/j.ijheatmasstransfer.2014.08.088
Wang, L.; Zhong, X.H.; Zhao, Y.X.; Tao, S.Y.; Zhang, W.; Wang, Y.; Sun, X.G.: Design and optimization of coating structure for the thermal barrier coatings fabricated by atmospheric plasma spraying via finite element method. J. Asian Ceram. Soc. 2, 102–116 (2014). https://doi.org/10.1016/j.jascer.2014.01.006
Wakashima, K.; Tsukamoto, H.: Mean-field micromechanics model and its application to the analysis of thermomechanical behaviour of composite materials. Mater. Sci. Eng. A 146(1–2), 291–316 (1991). https://doi.org/10.1016/0921-5093(91)90284-T
Tsukamoto, H.: Review micromechanical approach toward thermomechanical of metal matrix composites. ISIJ Int. 32, 883–892 (1992)
Liu, G.R.: A step-by-step method of rule-of-mixture of fiber- and particle-reinforced composite materials. Compos. Struct. 40, 313–322 (1997). https://doi.org/10.1016/S0263-8223(98)00033-6
He, Y.: Rapid thermal conductivity measurement with a hot disk sensor: part 2. Characterization of thermal greases. Thermochim. Acta 436, 130–134 (2005). https://doi.org/10.1016/j.tca.2005.07.003
Adamczyk, W.P.; Kruczek, T.; Moskal, G.; Białecki, R.A.: Nondestructive technique of measuring heat conductivity of thermal barrier coatings. Int. J. Heat Mass Transf. 111, 442–450 (2017). https://doi.org/10.1016/j.ijheatmasstransfer.2017.03.126
Białas, M.: Finite element analysis of stress distribution in thermal barrier coatings. Surf Coat. Technol. 202, 6002–6010 (2008). https://doi.org/10.1016/j.surfcoat.2008.06.178
Wang, L.; Fan, Q.; Liu, Y.; Li, G.; Zhang, H.; Wang, Q.; Wang, F.: Simulation of damage and failure processes of thermal barrier coatings subjected to a uniaxial tensile load. Mater. Des. 86, 89–97 (2015). https://doi.org/10.1016/j.matdes.2015.07.118
Kyaw, S.; Jones, A.; Jepson, M.A.E.; Hyde, T.; Thomson, R.C.: Effects of three-dimensional coating interfaces on thermo-mechanical stresses within plasma spray thermal barrier coatings. Mater. Des. 125, 189–204 (2017). https://doi.org/10.1016/j.matdes.2017.03.067
Wang, L.; Shao, F.; Zhong, X.H.; Ni, J.X.; Yang, K.; Tao, S.Y.; Wang, Y.: Tailoring of self-healing thermal barrier coatings via finite element method. Appl. Surf. Sci. 431, 60–74 (2018). https://doi.org/10.1016/j.apsusc.2017.06.025
Verma, R.; Randhawa, J.S.; Kant, S.; Suri, N.M.: Characterization studies of slurry-sprayed mullite-nickel coatings on ASTM 1018 steel. Arab. J. Sci. Eng. (2019). https://doi.org/10.1007/s13369-019-03753-6
Qiao, J.H.; Bolot, R.; Liao, H.; Bertrand, P.; Coddet, C.: A 3D finite-difference model for the effective thermal conductivity of thermal barrier coatings produced by plasma spraying. Int. J. Therm. Sci. 65, 120–126 (2013). https://doi.org/10.1016/j.ijthermalsci.2012.09.008
Han, M.; Huang, J.; Chen, S.H.: A parametric study of the Double-Ceramic-Layer Thermal Barrier Coating Part II: optimization selection of mechanical parameters of the inside ceramic layer based on the effect on the stress distribution. Surf Coat. Technol. 238, 93–117 (2014). https://doi.org/10.1016/j.surfcoat.2013.10.053
Han, M.; Zhou, G.; Huang, J.; Chen, S.H.: A parametric study of the double-ceramic-layer thermal barrier coatings part I: optimization design of the ceramic layer thickness ratio based on the finite element analysis of thermal insulation (take LZ 7 C 3/8YSZ/NiCoAlY DCL-TBC for an example). Surf Coat. Technol. 236, 500–509 (2013). https://doi.org/10.1016/j.surfcoat.2013.10.049
Vaßen, R.; Kerkhoff, G.; Stöver, D.: Development of a micromechanical life prediction model for plasma sprayed thermal barrier coatings. Mater. Sci. Eng. A 303, 100–109 (2001). https://doi.org/10.1016/S0921-5093(00)01853-0
Alexander, J.F.S.: CRC Materials Science and Engineering Databook. CRC Press, Boca Raton (2001). https://doi.org/10.1201/9781420038408
Barton, A.F.M.: CRC Handbook of Solubility Parameters and Other Cohesion Parameters, 2nd edn. CRC Press, New York (2017). https://doi.org/10.1201/9781315140575
He, Y.: Rapid thermal conductivity measurement with a hot disk sensor: part 1. Theoretical considerations. Thermochim. Acta 436, 122–129 (2005). https://doi.org/10.1016/j.tca.2005.06.026
He, Y.: Heat capacity, thermal conductivity, and thermal expansion of barium titanate-based ceramics. Thermochim. Acta 419, 135–141 (2004). https://doi.org/10.1016/j.tca.2004.02.008
Ajlan, S.A.: Measurements of thermal properties of insulation materials by using transient plane source technique. Appl. Therm. Eng. 26, 2184–2191 (2006). https://doi.org/10.1016/j.applthermaleng.2006.04.006
Lim, L.Y.; Meguid, S.A.: Temperature dependent dynamic growth of thermally grown oxide in thermal barrier coatings. Mater. Des. 164, 107543 (2019). https://doi.org/10.1016/j.matdes.2018.107543
Pabst, W.; Gregorová, E.; Uhlířová, T.; Musilová, A.: Elastic properties of mullite and mullite-containing ceramics part 1: theoretical aspects and review of monocrystal data. Ceram. Silik. 57, 265–274 (2013)
Ledbetter, H.; Kim, S.; Balzar, D.; Crudele, S.; Kriven, W.: Elastic properties of mullite. J. Am. Ceram. Soc. 81, 1025–1028 (2005). https://doi.org/10.1111/j.1151-2916.1998.tb02441.x
Nikolaev, V.P.; Myshenkova, E.V.; Pichugin, V.S.; Sinitsyn, E.N.; Khoroshev, A.N.: Temperature effect on the mechanical properties of composite materials. Inorg. Mater. (2014). https://doi.org/10.1134/S002016851415014X
Ramalho, A.; Braga De Carvalho, M.D.; Antunes, P.V.: Effects of temperature on mechanical and tribological properties of dental restorative composite materials. Tribol. Int. 63, 186–195 (2013)
Sadowski, T.; Golewski, P.: Loadings in Thermal Barrier Coatings of Jet Engine Turbine Blades. An Experimental Research and Numerical Modeling. Springer, Singapore (2016). https://doi.org/10.1007/978-981-10-0919-8
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Naseem, M., Verma, R. & Kango, S. Thermo-mechanical Evaluation of Slurry-Sprayed Multi-layered Coatings. Arab J Sci Eng 45, 9449–9470 (2020). https://doi.org/10.1007/s13369-020-04793-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s13369-020-04793-z