Determining a critical strain for APS thermal barrier coatings under service relevant loading conditions

Despite the huge progress made in recent years in analysing the degradation behavior and the reliability of thermal barrier coating systems, there is still some deficit in the capability to predict damage evolution in terms of crack initiation and crack growth, which ultimately leads to macroscopic delamination and spallation of the coating system. In order to obtain this prediction capability, a fundamental understanding of the damage evolution processes under isothermal, thermo-cyclic and under thermo-mechanical loading conditions has to be developed.The aim of the presented work is to determine the critical strain, i.e. the strain at which cracking initiates, and to analyse the evolution of a network of cracks for widely used atmospheric plasma sprayed (APS) thermal barrier coating (TBC) systems. The TBC system has been exposed in our study to service relevant loading conditions, namely to thermal gradient mechanical fatigue (TGMF). TGMF tests for in-phase as well as out-of-phase loading cycles were performed on hollow cylindrical specimens made of the single crystal super alloy CMSX-4, loaded mechanically in 〈0 0 1〉 orientation, and being coated with a duplex system comprised of a CoNiCrAlY bond coat and a 8 wt.% Yttria partially stabilized Zirconia (YSZ) TBC. The CoNiCrAlY bond coat was deposited by Low Pressure Plasma Spraying (LPPS), while the ceramic top coat was deposited using the APS process. The loading cycles were chosen to represent an industrial gas turbine engine. Critical strains measured for delamination (within the ceramic coating or at the CoNiCrAlY – TBC interface) and through cracking, i.e. segmentation of the ceramic top coat was determined using a special compression test equipped with in situ acoustic emission technique. The mechanical testing was performed at room temperature after TGMF exposure. In order to study the impact of thermally grown oxide (TGO), specimens have been TGMF tested in the “as received” conditions as well as after isothermal aging (up to 3000 h at 1000 °C). To correlate the signal obtained by acoustic emission (AE) with the evolution of (micro-) cracks, the specimens have been carefully sectioned and investigated by standard metallographic means.The measured critical strains are used as a data basis for a strain-based lifetime model developed for isothermal and cyclic oxidation as well as thermo-mechanical loading. The lifetime model considers two failure modes, namely delamination and (vertical) through cracking.Metallographically obtained crack patterns within the TBC system have been incorporated into finite element models to quantify stress–relaxation as a consequence of damage evolution in the TBC system.The observations show that thermal gradient fatigue loading under in-phase loading leads to a shorter lifetime compared to out-of-phase loading.For the delamination mode, the critical strain values of the model are in good agreement with the experimental data of the TGMF experiments. The modeled critical strain for through cracking, on the other hand, is consistently lower than the experimentally determined failure strains, implying that the model describes the failure situation in a conservative manner.     

Development of Al–Mn–Mg 3004 alloy for applications at elevated temperature via dispersoid strengthening

In this study, the potential applications of Al–Mn–Mg 3004 alloy at elevated temperature have been evaluated through the systematic study of the precipitation behavior of α-Al(MnFe)Si dispersoids and their effect on material properties during precipitation treatment and long-term thermal holding. The results demonstrate a significant dispersion strengthening effect caused by the precipitation of fine uniformly distributed dispersoids during precipitation treatment. The peak compression yield strength (YS) at 300 °C of the experimental 3004 alloy can reach as high as 78 MPa due to a large volume fraction (~ 2.95 vol.%) of α-Al(MnFe)Si dispersoids. The dispersoids are found to be thermally stable at 300 °C for up to 1000 h of holding, leading to consistently high mechanical performance and creep resistance. The superior and stable YS and creep resistance at 300 °C enables the 3004 alloy to be applied to weight-sensitive applications at elevated temperatures.     

Effect of environment atmosphere on thermal shock resistance of the ZrB2–SiC–graphite composite

The thermal shock resistance of the ZrB₂–SiC–graphite composite was evaluated by measuring the retention of the flexural strength after the electrical resistance heating to the temperature ranging from 1000 °C up to 2500 °C. The experiment was operated in two different environment atmospheres (pure oxygen and low oxygen partial pressure which mixed O₂ and Ar with 1:9) at total pressure 2000 Pa. The residual strength for the specimen decreased gradually as the temperature increased up to 2200 °C, and it was slightly higher when heated in low oxygen partial pressure environment than in pure oxygen. In contrast to the specimen heated in low oxygen partial pressure environment, the residual strength for the specimen in pure oxygen increased steeply as the temperature increased from 1600 °C up to 1800 °C. The analysis of the SEM observations combined with EDS confirmed that the surface oxidation played a positive role in the thermal shock resistance of the ZrB₂–SiC–graphite composite with different environment atmospheres. The results here pointed out a potential method for charactering the effect of environment atmosphere on thermal shock resistance of the ZrB₂–SiC–graphite composite.     

The fabrication of porous corundum spheres with core-shell structure for corundum-spinel castables

Porous corundum spheres (PCSs) that possess core-shell structure were fabricated by foaming and wet granulation method and used as aggregates to prepare the porous corundum-spinel castables (PCSCs). The microstructure and properties of PCS and PCSC have been studied. The results showed that the microporous shell and macroporous core were formed in PCS with the bulk density of 3.08 g · cm^− 3 and the apparent porosity of 10.9%. In addition, the median pore diameter of PCS is 6.47 μm. The thermal conductivity of PCSC is 0.753 W/m · K at 1000 °C, and PCSC showed the higher corrosion index and better resistance to slag penetration than corundum-spinel castables (CSC) using the tabular corundum as aggregates. Compared with CSC, the bulk density of PCSC is decreased by 6.3% at 110 °C, 4.6% at 1550 °C, and the thermal conductivity decreased by 13.3–21.4% from 200 °C to 1000 °C. The results demonstrated that PCS with designed core-shell structure can achieve the trade-off between thermal conductivity and corrosion resistance.     

Stress–strain behaviour and abrupt loss of stiffness of geopolymer at elevated temperatures

This paper reports stress versus strain curves of geopolymer tested while the specimens were kept at elevated temperatures, with the aim to study the fire resistance of geopolymer. Tests were performed at temperatures from 23 to 680 °C and after cooling. Hot strengths of geopolymer increased when the temperature increased from 290 to 520 °C, reaching the highest strength at 520 °C, which is almost double that of its initial strength at room temperature. However, glass transition behaviour was observed to occur between 520 and 575 °C, which was characterised by abrupt loss of stiffness and significant viscoelastic behaviour. The glass transition temperature is determined to be 560 °C. Further, the strength reductions occurred during cooling to room temperature. This is attributed to the damage due to brittle nature of the material making it difficult to accommodate thermal strain differentials during cooling phase.     

High-velocity impact damage behavior of plain-woven SiC/SiC composites after thermal loading

This study investigates characteristics of foreign-object damage in plain-woven SiC/SiC composites after thermal loading. High-speed impact tests were conducted on virgin specimens, thermally exposed specimens, and thermally shocked specimens, in which the maximum temperature during thermal loading was 600 °C or 1000 °C. An oxide layer was generated on the specimen surface by thermal loading at 1000 °C. Damaged areas on the front and back surfaces induced by particle impact were independent of thermal loading. However, in specimens thermally loaded at 1000 °C, brittle failure, i.e. cone cracking without fiber pull-out, occurred due to oxidation of the fiber/matrix interfaces, and the ballistic limit velocity significantly decreased. Finally, the ballistic limit is predicted using static strength properties, and the effect of thermal loading on impact resistance is discussed.     

Effect of strain rate on the dynamic compressive mechanical behaviors of rock material subjected to high temperatures

Strain rate is not only an important measure to characterize the deformation property, but also an important parameter to analyze the dynamic mechanical properties of rock materials. In this paper, by using the SHPB test system improved with high temperature device, the dynamic compressive tests of sandstone at seven temperatures in the range of room temperature to 1000 °C and five impact velocities in the range of 11.0–15.0 m/s were conducted. Investigations were carried out on the influences of strain rate on dynamic compressive mechanical behaviors of sandstone. The results of the study indicate that the enhancement effects of strain rates on dynamic compressive strength, peak strain, energy absorption ratio of sandstone under high temperatures still exist. However, the increase ratios of dynamic compressive strength, peak strain, and energy absorption ratio of rock under high temperature compared to room temperature have no obvious strain rate effects. The temperatures at which the strain rates affect dynamic compressive strength and peak strain most, are 800, and 1000 °C, respectively. The temperatures at which the strain rates affect dynamic compressive strength and peak strain weakest, are 1000 °C, and room temperature, respectively. At 200 and 800 °C, the strain rate effect on energy absorption ratio are most significant, while at 1000 °C, it is weakest. There are no obvious strain rate effects on elastic modulus and increase ratio of elastic modulus under high temperatures. According to test results, the relationship formula of strain rate with high temperature and impact load was derived by internalizing fitting parameters. Compared with the strain rate effect at room temperature condition, essential differences have occurred in the strain rate effect of rock material under the influence of high temperature.     

Dissolution kinetics of δ phase and its influence on the notch sensitivity of Inconel 718

The dissolution kinetics of δ phase in Inconel 718 at 980 °C, 1000 °C and 1020 °C and its influence on high temperature notch sensitivity have been studied using a quantitative X-ray diffraction (XRD) method and high temperature stress rupture life tests of notched specimens. The amount of δ phase decreases gradually during holding time at 980 °C, 1000 °C and 1020 °C. The δ phase will be fully dissolved in the austenitic matrix at 1020 °C for more than 2 h. A certain amount of δ phase still exists after holding at 980 °C and 1000 °C for times up to 6 h; the amount remaining are 3 wt.% and 0.6 wt.%, respectively. The dissolution rate remains at a high level at the beginning, and then decreases gradually with an increase of holding time. A dynamic equilibrium state can be approached after holding at 980 °C for more than 30 min and at 1000 °C for more than 2 h. The alloy with δ phase amounts higher than 0.62 wt.% does not exhibit notch sensitivity, whereas serious notch sensitivity exists if the concentration is below 0.43 wt.%.     

Investigation of the compressive creep behavior of AZ91D magnesium alloy

The creep resistance of AZ91D alloy has been studied in uniaxial compression tests at temperature ranges from 275 °C to 325 °C. The initial microstructure of the alloy consists of α phase and β phase precipitated in the grain boundary. The minimum creep rate dependence on applied stress and the temperature is also analyzed in detail. We find that the stress exponent n is close to the theoretical values (3 or 5) and the activation energy Q for creep varies from 121 kJ/mol to 171 kJ/mol. Creep could be controlled by high-temperature climb and cross-slip of dislocation at different temperatures.     

Ultrasonic fatigue of a single crystal Ni-base superalloy at 1000 °C

An ultrasonic fatigue testing system capable of operating at temperatures up to 1000 °C has been developed and utilized to study the fatigue behavior of a single crystal superalloy (PWA 1484) at a temperature of 1000 °C and loading frequency of approximately 20 kHz. The stress-life data generated from the ultrasonic testing system were comparable to those from conventional servo-hydraulic fatigue tests for similar single crystal alloys. Interior Ta-rich carbides were the major microstructural feature responsible for crack initiation in the alloy. Crack growth under ultrasonic loading frequency at 1000 °C for PWA 1484 occurred in a crystallographic manner on {1 1 1} octahedral slip planes, in contrast to the normal Mode-I growth mode typically observed for single crystal superalloys at high temperature (>850 °C) with conventional servo-hydraulic loading frequencies (<100 Hz).     

Ni24.7Ti50.3Pd25.0 high temperature shape memory alloy with narrow thermal hysteresis and high thermal stability

High temperature shape memory alloys with operating temperatures above 100 °C are in demand for use as solid-state thermal actuators in aerospace, automobile and other engineering applications. The present study deals with transformation behaviour and thermal stability of Ni_24.7Ti_50.3Pd_25.0 (at.%) high temperature shape memory alloy, in cast and homogenized condition. The martensite finish temperature and transformation hysteresis of the alloy were determined to be 181.0 °C and ∼8.5 °C respectively. The alloy showed high stability upon stress-free thermal cycling, variation in transformation temperatures being ±1 °C. The narrow thermal hysteresis and high thermal stability of the alloy upon transformation cycling has been discussed and correlated with its microstructural features, activation energy and elastic strain energy of thermoelastic martensitic transformation. The alloy exhibited modulus of ∼82 GPa and hardness of ∼4.7 GPa in martensite phase.     

Improving the hot corrosion resistance of plasma sprayed ceria–yttria stabilized zirconia thermal barrier coatings by laser surface treatment

Ceria–yttria stabilized zirconia (CYSZ) thermal barrier coatings (TBCs) were deposited by air plasma spraying on NiCoCrAlY-coated Inconel 738LC substrates. After that, the surface of plasma sprayed CYSZ TBCs were glazed using a pulsed Nd:YAG laser. The effects of laser glazing on hot corrosion resistance of the coatings were evaluated in presence of 45 wt%Na₂SO₄ + 55 wt%V₂O₅ corrosive molten salt at 1000 °C. The results revealed that the hot corrosion resistance of plasma sprayed CYSZ TBCs were enhanced more than twofold by laser surface glazing due to reducing specific reactive area of the dense glazed surface layer and consequently, decreasing the reaction between molten salt and zirconia stabilizers.     

Effect of the thermal cycle on the hot ductility and fracture mechanisms of a C–Mn steel

Transverse cracking on the surface of continuously cast steel products has been one of the main problems of this stage in steelmaking for many years. The incidence of this problem has been found in microalloyed steels as well as in some plain carbon steels containing residual elements. In this work, the hot ductility and fracture mechanisms of a C–Mn steel containing 0.6%Cu and 0.053%Sn as residual elements have been evaluated. To simulate the thermo-mechanical conditions of the straightening operation, tensile tests were carried out at temperatures ranging from 700 to 1100 °C with an initial strain rate of 5 × 10⁻³ s⁻¹. Specimens were subjected to three different reheating temperatures prior to the hot ductility test, including 1100 °C, 1330 °C and melting. After each test, the reduction in area of the samples tested to fracture was used as a measure of the hot ductility. The fracture surfaces were then examined by scanning electron microscopy. The widest and deepest ductility trough was obtained for the specimens tested after melting; for these conditions brittle fractures are interdendritic showing very low ductility. After reheating at 1330 °C, fracture features showed intergranular fracture combined with some plastic deformation corresponding to the test temperature. Reheating at 1100 °C produced a finer microstructure and the fracture features showed a mixture of intergranular with some interdendritic features. Also, ductile behaviours were associated with void coalescence. The different results obtained depending on the thermal cycle can be attributed to the presence of the residual elements in the steel through different segregation and precipitation patterns.     

The effects of Ta on the stress rupture properties and microstructural stability of a novel Ni-base superalloy for land-based high temperature applications

A novel polycrystalline Ni-base superalloy was developed for land-based high temperature applications, such as isothermal forging dies and industrial gas turbines. The alloy possessed surprisingly high stress rupture life of 52 h at 1100 °C/118 MPa which is comparable to the first generation single crystal (SC) superalloy and exhibited good microstructural stability. The effects of Ta addition on the phase change, stress rupture properties and microstructural stability of the alloy were investigated. The results indicated that Ta is a γ′-former and promotes the formation of eutectic γ′. The alloys with ∼7 vol.% eutectic γ′ possess higher stress rupture life at 1100 °C/118 MPa than the alloys with higher ∼20 vol.% eutectic. However, ∼20 vol.% excessive eutectic phases will enhance the stress rupture life at intermediate temperature of 760 °C for 686 MPa but weaken high temperature stress rupture properties. The (Al + Ta) content over 14.4 at.% led to the formation of large amounts of eutectic γ′ and exceeded the solubility of W and Mo in the residue liquid pool, which then promoted the precipitation of primary α-(W,Mo) and M₆C phases. Tantalum was also found as a strong MC carbides forming element. The order of ability to form monocarbide decreased from NbC to TaC to TiC. 6Al–0Ta (wt.%) alloys possessed good microstructural stability with no harmful topologically close-packed (TCP) phases being observed after thermal exposure at 850 °C/3000 h, 900 °C/1000 h. Only trace amounts of secondary plate-like M₆C carbides appeared in Ta-free and 5Al–4Ta (wt.%) alloys at 1100 °C/100–500 h. However, excessive Ta addition will destabilize the alloy and large amounts of secondary plate-like M₆C carbides precipitated after thermal exposure at 1100 °C. The transmission electron microscopy (TEM) and selected area electron diffraction (SAED) results showed the existence of the plate-like M₆C carbides.     

Experimental study on critical breaking stress of float glass under elevated temperature

Cracking and subsequent fallout of glass may significantly affect fire dynamics in compartments. Moreover, the breaking tensile stress of glass, a crucial parameter for breakage occurrence, is the least well known among mechanical properties. In this work, a series of experiments were conducted, through mechanical tensile tests, to directly measure the breaking stress of float glass using Material Testing System 810 apparatus. Clear, ground and coated glass samples with a thickness of 6 mm were measured under ambient conditions, with a room temperature of 25 °C. The breaking stress of smooth glass samples was also measured at 75 °C, 100 °C, 125 °C, 150 °C, 200 °C, 300 °C and 400 °C, respectively. The results show that surface treatment may decrease the critical tensile stress of glass panes. The average breaking stress also fluctuates considerably, from 26.60 to 35.72 MPa with the temperature variations investigated here. At approximately 100 °C, critical stress reached the minimum value at which glass breakage occurs more easily. In addition, the thermal expansion coefficient was established using a thermal dilatometer, to obtain the maximum temperature difference float glass can withstand. It is intended that these results will provide some practical guidelines for fire safety engineers.     

Thermal aging effect on the ratcheting-fatigue behavior of Z2CND18.12N stainless steel

The uniaxial tensile and ratcheting-fatigue behaviors of the Z2CND18.12N austenitic stainless steel at room temperature were studied with different thermal aging periods (from 1 h to 500 h) at different thermal aging temperatures (500 °C and 700 °C). The thermal aging process resulted in apparent changes in the ratcheting behavior and the ratcheting-fatigue life. The precipitates under different thermal aging conditions were identified by SEM observation. Considering the deterioration of the material induced by thermal aging process, aging damage factor was introduced to predict the ratcheting-fatigue life, which resulted in good prediction for all the thermal aging conditions.     

Thermal history induced variable relaxor behavior in the high TC ternary ferroelectric 0.6Bi(Mg1/2Ti1/2)O3–0.05Bi(Zn1/2Ti1/2)O3–0.35PbTiO3

Studies carried out on a perovskite-structured rhombohedral 0.6Bi(Mg_1/2Ti_1/2)O₃–0.05Bi(Zn_1/2Ti_1/2)O₃–0.35PbTiO₃ (xBZT–yBMT–zPT) ceramic quenched from temperatures below 1000 °C show that the dielectric properties are dramatically altered by the thermal history. Samples quenched from temperatures 650 °C–900 °C show classical ferroelectric switching behavior that is not observed on either side of this temperature range. The quenched states lose their switchable ferroelectric properties when heated to temperatures as low as 400 °C. The results demonstrate for the first time that the dielectric and electromechanical response, as observed at room temperature, can be varied between normal to relaxor behavior by changing thermal quenching conditions.     

Fatigue crack growth and damage characteristics of high-speed rail at low ambient temperature

Low temperature can be a significant problem affecting safety and maintenance of railway. In this study, the fatigue crack growth rate and rolling contact fatigue damage behaviors of high-speed rail material under different temperature conditions were investigated by a series of experiments. The results indicate that the stress and strength of rail material increase with the decrease of ambient temperature. The crack growth rate at 0 °C and − 20 °C is similar with that at 20 °C. While, when the temperature decreases to − 60 °C, the growth rate of crack increases sharply. The promotion of rail embrittlement at low temperature accompanied with the action of high stress causes the rapid failure and increase of surface crack length and subsurface crack damage. Meanwhile, three crack growth mechanism models at different temperatures can be inferred. The brittle fracture mode is increasingly apparent with the temperature decreasing.     

Intermediate temperature brittleness and directional coarsening behavior of nickel-based single-crystal superalloy DD6

The microstructure of the nickel-based single-crystal superalloy DD6 after tensile deformation has been studied by transmission electron microscopy (TEM) with an energy-dispersive X-ray spectroscopy (EDS). The samples were strained to fracture at room temperature, 650 °C, 850 °C and 1020 °C along the [001] orientation. The results indicate that the yield strength at 650 °C is superior to that at room temperature (20 °C), 850 °C and 1020 °C, but low ductility was observed at 650 °C. It is demonstrated that the intermediate temperature brittleness (ITB) behavior was caused by the change of the deformation mechanism at intermediate temperature. At high temperature, the γ′ precipitates coarsening directionally along the direction perpendicular to the stress axis. This can be attributed to the directional diffusion of the chemical elements.