Cracking in coating-substrate composites with multi-layered and FGM coatings

This investigation evaluates, by finite element method, the stress intensity factors (SIF) of cracked multi-layered and functionally graded material (FGM) coatings of a coating-substrate composite, due to the action of uniform normal stress on the crack surfaces. The substrate is assumed to be homogeneous material, while the coating consists of multi-layered media or sigmoid FGMs. The sigmoid FGM is a kind of FGM in which the material properties of the coating are governed by two power-law functions of volume fractions such that the functions of the material property represent sigmoid distributions in the thickness direction, simply called S-FGM in this paper. For the multi-layered coatings, one, two, and four-layered homogeneous coatings with stepwise changing volume fractions are considered. The primary problem addressed herein is the appearance of a crack in the coating surface and its expansion into the substrate along the direction perpendicular to the interface between the coating and the substrate. The results show that if the coating is stiffer than the substrate, a crack in a one-layered coating is much more susceptible to propagation into the substrate than a crack in the two- or four-layered coating. But crack growth can be effectively averted by using an S-FGM coating. However, if the coating is softer than the substrate, the S-FGM coating behaves like a bridge to connect the soft coating and the stiff substrate, and facilitates the expansion of the crack expanding into the substrate. Whereas the one-layered coating can more effectively prevent the crack from propagating into the substrate than can the two- or four-layered coating. The investigation also indicates that the material gradations of S-FGMs influence SIFs obviously only when the crack tip is inside the coating that is stiffer than the substrate. As the crack extends through the coating and into the substrate, the material gradation of the S-FGM coating and the material mismatch of the multi-layered coating slightly bear on the values of SIF.     

Geometry effects of substrate and coating layers on the thermal stress response of FGM structure

Summary Due to transient temperature change, the plane strain elastic-plastic problem for a functionally graded material (FGM) bonded to a homogeneous coating layer and a metal substrate is considered by the use of the finite element method (FEM). The substrate and the coating are assumed to be aluminum and partially stabilized zirconia, respectively. The FGM layer is a particulate composite of aluminum and partially stabilized zirconia with volume fractions continuously varying through the thickness. Generally in high temperature applications, the FGM system is sandwiched between a substrate layer and a coating layer. The coating layer increases the protection from heat but decreases the thermal shock resistance while the substrate layer increases the rigidity of the structure and decreases strength-related properties at high temperature. In order to compromise the thickness of both the coating and substrate layers, different values of the substrate and coating thickness are studied in order to evaluate their effects on the thermal stress response of the FGM structure. Since the main objective of the FGMs is using them in different applications with severe thermal loading conditions, the thermal stresses may be so high that some reinforcements may be fractured and/or debonded from the matrix giving a weakening effect instead of a reinforcing one. Hence, the behaviors of the reinforcements and the matrix are essential to be studied. In this regard, microscopic constitutive equations along with the temperature-dependent properties of the constituent materials are considered to enable us obtaining more realistic results of thermal stresses. Since the FGM structures are fabricated at high temperatures, thermal residual stresses are produced. In order to find out the importance of the consideration of the residual stresses arising from the fabrication process, the FGM structure with stress-free conditions is heated to the operating temperature, and its thermal stress response is compared with that one where the residual stresses are taken into account. Also, several functional forms of gradation of the constituents in the FGM layer are examined to reach the optimum profile giving the minimum stress level for the FGM structure under thermo-elasto-plastic behavior.     

Three-dimensional analysis of a functionally graded coating/substrate system of finite thickness

The concept of functionally graded material (FGM) is currently actively explored in coating design for the purpose of eliminating the mismatch of thermomechanical properties at the interfaces and thus increasing the resistance of coatings to functional failure. In the present paper, three-dimensional elastic deformation of a functionally graded coating/substrate system of finite thickness subjected to mechanical loading is investigated. A comparative study of FGM versus homogeneous coating is conducted to examine the effect of the coating type on stress and displacement fields in the system.     

含FGM的涂层结构中热残余应力的分析与优化

本文利用有限元方法和优化理论,对含FGM(Functionally Graded Materials)层的热喷涂构件中的残余应力进行了数值分析,并获得了FGM内各组份体积含量分布的最优化形式和参数p.同时,我们也研究了喷涂构件的几何形状、涂层及基底的材料性能对于p的影响规 律。在本文的分析中,考虑了基底材料和FGM的塑性变形以及其性能对于温度的依赖。本文 的工作将有利于含FGM层的热喷涂构件的设计与生产。     

Interface cracking between functionally graded coatings and a substrate under antiplane shear

Coating technology plays a significant role in a number of applications such as high temperatures, corrosion, oxidation, wear, and interface. In this paper, we investigate the interface cracking between ceramic and/or functionally graded coatings (FGM coatings) and a substrate under antiplane shear. Four coating models are considered, namely single layered homogeneous coating, double layered piece-wise homogeneous coating, single layered FGM coating and double layered coating with an FGM bottom coat. Mode III stress intensity factors (SIFs) are calculated for the different coating models. In the case of μ_L > μ₀ where μ₀ is the shear modulus of the substrate and μ_L the shear modulus of the material at the surface of the coating, it is found that the single layered FGM coating reduces SIF slightly, whereas the coating system with a top homogeneous layer and a thin FGM bottom layer reduces SIF significantly. In the case of μ_L < μ₀ the SIF is found to be larger for the FGM coatings than for the homogeneous coatings. The FGM coating, however, may still be superior to homogeneous coatings in this case as FGM coatings usually provide better bonding strength between the coating and substrate. Finally, the applicability of the SIF concept in the fracture of FGM coatings is discussed. Large modulus gradients in thin coatings may seriously restrict the application of SIFs as the SIF-dominant zone may fall into the crack tip nonlinear deformation and damage zone. The same argument exists for some interphase models in interface crack solutions.     

Three dimensional fracture analysis of FGM coatings under thermomechanical loading

The main objective of this study is to examine the three dimensional surface crack problems in functionally graded coatings subjected to mode I mechanical or transient thermal loading. The surface cracks are assumed to have a semi-elliptical crack front profile of arbitrary aspect ratio. The cracks are embedded in the functionally graded material (FGM) coating which is perfectly bonded to a homogeneous substrate. A three dimensional finite element method is used to solve the thermal and structural problems. Collapsed 20-node isoparametric elements are utilized to simulate the strain singularity around the crack front. The stress intensity factors are computed by using the displacement correlation technique. Four different coating types are considered in the analyses which have homogeneous, ceramic-rich (CR), metal-rich (MR) and linear variation (LN) material composition profiles. In the mechanical loading problems, the composite medium is assumed to be subjected to fixed-grip tension or three point bending. In the thermal analysis, a transient residual stress problem is considered. The stress intensity factors calculated for FGM plates are in good agreement with the previously published results on three dimensional surface cracks. The new results provided show that maximum stress intensity factors computed during transient thermal loading period for the FGM coatings are lower than those of the homogeneous ceramic ones.     

Transient thermal stress analysis of an edge crack in a functionally graded material

An edge crack in a strip of a functionally graded material (FGM) is studied under transient thermal loading conditions. The FGM is assumed having constant Young's modulus and Poisson's ratio, but the thermal properties of the material vary along the thickness direction of the strip. Thus the material is elastically homogeneous but thermally nonhomogeneous. This kind of FGMs include some ceramic/ceramic FGMs such as TiC/SiC, MoSi₂/Al₂O₃ and MoSi₂/SiC, and also some ceramic/metal FGMs such as zirconia/nickel and zirconia/steel. A multi-layered material model is used to solve the temperature field. By using the Laplace transform and an asymptotic analysis, an analytical first order temperature solution for short times is obtained. Thermal stress intensity factors (TSIFs) are calculated for a TiC/SiC FGM with various volume fraction profiles of the constituent materials. It is found that the TSIF could be reduced if the thermally shocked cracked edge of the FGM strip is pure TiC, whereas the TSIF is increased if the thermally shocked edge is pure SiC.     

Thermo-mechanical behavior of a viscoelastic FGMs coating containing an interface crack

In this paper the plane thermo-mechanical behavior of a crack in a viscoelastic functionally graded materials (FGMs) coating with arbitrary material properties bonded to a homogeneous substrate is studied. In order to avoid the complex forms that describe the viscoelastic properties of FGMs, a multi-layered model for the FGMs coating is developed. The compliance and thermal conductivity in the multi-layered model linearly vary in each layer. In this mixed boundary value problem, the system is reduced to singular integral equations and solved numerically with the Lobatto-Chebyshev collocation technique. Using the correspondence principle and Laplace transform, the problem of an interface crack between a homogeneous substrate and a viscoelastic FGMs is solved. Some numerical examples are given to demonstrate the accuracy, efficiency and versatility of the multi-layered model. The numerical results confirm that the fracture toughness of materials can be greatly improved by the graded variation of material parameters. It is also confirmed that the specific variation of material parameters greatly influences the fracture behavior of viscoelastic FGMs coating.     

A further discussion of nonlinear mechanical behavior for FGM beams under in-plane thermal loading

Due to the variation in material properties through the thickness, bifurcation buckling cannot generally occur for plates or beams made of functionally graded materials (FGM) with simply supported edges. Further investigation in this paper indicates that FGM beams subjected to an in-plane thermal loading do exhibit some unique and interesting characteristics in both static and dynamic behaviors, particularly when effects of transverse shear deformation and the temperature-dependent material properties are simultaneously taken into account. In the analysis, based on the nonlinear first-order shear deformation beam theory (FBT) and the physical neutral surface concept, governing equations for both the static behavior and the dynamic response of FGM beams subjected to uniform in-plane thermal loading are derived. Then, a shooting method is employed to numerically solve the resulting equations. The material properties of the beams are assumed to be graded in the thickness direction according to a simple power law distribution in terms of the volume fractions of the constituents, and to be temperature-dependent. The effects of material constants, transverse shear deformation, temperature-dependent material properties, in-plane loading and boundary conditions on the nonlinear behavior of FGM beams are discussed in detail.     

功能梯度表面涂层热锻模的仿真设计与分析

针对热锻模损伤主要发生在模具表面的情况,构想使用梯度功能材料对均质材料制造的热锻模进行表面处理,阐述了梯度材料锻模表面涂层的设计方法,建立了基于Deform软件的热锻成形有限元模型,分析对比了均质热锻模与梯度材料表面涂层热锻模在锻造生产后的温度场和应力场,从而论证了在热锻模表面进行梯度材料表面复合涂层处理的优越性。     

Postbuckling of pressure-loaded FGM hybrid cylindrical shells in thermal environments

A postbuckling analysis is presented for a functionally graded cylindrical shell with piezoelectric actuators subjected to lateral or hydrostatic pressure combined with electric loads in thermal environments. Heat conduction and temperature-dependent material properties are both taken into account. The temperature field considered is assumed to be a uniform distribution over the shell surface and varied in the thickness direction and the electric field considered only has non-zero-valued component E_Z. The material properties of functionally graded materials (FGMs) are assumed to be graded in the thickness direction according to a simple power law distribution in terms of the volume fractions of the constituents, and the material properties of both FGM and piezoelectric layers are assumed to be temperature-dependent. The governing equations are based on a higher order shear deformation theory with a von Kármán–Donnell-type of kinematic nonlinearity. A boundary layer theory of shell buckling is extended to the case of FGM hybrid laminated cylindrical shells of finite length. A singular perturbation technique is employed to determine the buckling pressure and postbuckling equilibrium paths. The numerical illustrations concern the postbuckling behavior of pressure-loaded, perfect and imperfect, FGM cylindrical shells with fully covered piezoelectric actuators under different sets of thermal and electric loading conditions. The results reveal that temperature dependency, temperature change and volume fraction distribution have a significant effect on the buckling pressure and postbuckling behavior of FGM hybrid cylindrical shells. In contrast, the control voltage only has a very small effect on the buckling pressure and postbuckling behavior of FGM hybrid cylindrical shells.     

Volume fraction optimization for step-formed functionally graded plates considering stress and critical temperature

Step-formed Functionally Graded Materials (FGMs) flat panels are investigated for volume fraction optimization by considering stress and critical temperature. The structure is composed of numerous layers with homogeneous and different isotropic material properties from ceramic to metal. Material properties are assumed to be temperature dependent, and remain constant in each layer. Further, the properties are assumed to be varied in the thickness direction according to a simple power law distribution in terms of the ceramic and metal volume fractions for the layer. The effective material properties of the plate are obtained by applying linear rule of mixtures for the layers. The 3-D finite element model is adopted to analyze more accurately the variation of material properties and temperature field in the thickness direction. For the various FGM volume fraction distributions and geometric parameters, mechanical stress analysis and thermo-mechanical buckling analysis are performed to get the critical conditions. Based on the results, the volume fraction optimization of the flat panels is performed for stress reduction and improving thermo-mechanical buckling behavior and compared with previous results.     

Optimization of material composition to minimize the thermal stresses induced in FGM plates with temperature-dependent material properties

A hybrid genetic algorithm with the complex method is developed for the optimization of the material composition of a multi-layered functionally graded material plate with temperature-dependent material properties in order to minimize the thermal stresses induced in the plate when it is subjected to steady-state thermal loads. In the formulation, the plate is artificially divided into an n _l -layered plate, and a weak-form-based finite layer method is developed to obtain the displacement and stress components induced in the n _l -layered plate using the Reissner mixed variational theorem. Two thermal conditions, namely the specified temperature and heat convection conditions, imposed on the top and bottom surfaces of the plate are considered. The through-thickness distributions of the volume fractions of the constituents are assumed as certain specific/non-specific function distributions, such as power-law, sigmoid, layerwise step and layerwise linear function distributions, and the effective material properties of the plate are estimated using the Mori–Tanaka scheme. Comparisons with regard to the minimization for the peak values of the stress ratios induced in the FGM plates with various optimal material compositions are conducted.     

Nonlinear thermal bending response of FGM plates due to heat conduction

Nonlinear thermal bending analysis is presented for a simply supported, shear deformable functionally graded plate without or with piezoelectric actuators subjected to the combined action of thermal and electrical loads. Heat conduction and temperature-dependent material properties are both taken into account. The temperature field considered is assumed to be a uniform distribution over the plate surface and varied in the thickness direction and the electric field considered only has non-zero-valued component E_Z. The material properties of functionally graded materials (FGMs) are assumed to be graded in the thickness direction according to a simple power law distribution in terms of the volume fractions of the constituents, and the material properties of both FGM and piezoelectric layers are assumed to be temperature-dependent. The governing equations of an FGM plate are based on a higher order shear deformation plate theory that includes thermo-piezoelectric effects. A two step perturbation technique is employed to determine the thermal load–deflection and thermal load–bending moment curves. The numerical illustrations concern nonlinear bending response of FGM plates without or with surface bonded piezoelectric actuators due to heat conduction and under different sets of electric loading conditions. The results reveal that for the case of heat conduction the nonlinear thermal bending responses are quite different to those of FGM plates subjected to transverse mechanical loads, and the temperature-dependency of FGMs could not be neglected in the thermal bending analysis.     

Nonlinear analysis of sandwich plates with FGM face sheets resting on elastic foundations

Nonlinear vibration, nonlinear bending and postbuckling analyses are presented for a sandwich plate with FGM face sheets resting on an elastic foundation in thermal environments. The material properties of FGM face sheets are assumed to be graded in the thickness direction according to a simple power law distribution in terms of the volume fractions of the constituents. The governing equation of the plate that includes plate-foundation interaction is solved by a two-step perturbation technique. The thermal effects are also included and the material properties of both FGM face sheets and homogeneous core layer are assumed to be temperature-dependent. The numerical results reveal that the foundation stiffness and temperature rise have a significant effect on the natural frequency, buckling load, postbuckling and nonlinear bending behaviors of sandwich plates. The results also reveal that the core-to-face sheet thickness ratio and the volume fraction distribution of FGM face sheets have a significant effect on the natural frequency, buckling load and postbuckling behavior of the sandwich plate, whereas this effect is less pronounced for the nonlinear bending, and is marginal for the nonlinear to linear frequency ratios of the same sandwich plate.     

Life assessment prognostic modelling for multi-layered coating systems using a multidisciplinary approach

The multidisciplinary approach has been adopted to model the formation and propagation of blistering effect for evaluation of useful coating life in the multi-layered coating–substrate system. A prognostic model of de-bonding driving force has been formulated as a function of material science, solid mechanics and fracture mechanics properties to estimate critical, safe and fail conditions of the coating–substrate system. The blister growth velocity rate is also included in the developed model to estimate the blister propagation as a function of diffusion-induced stress and residual stress. The proposed prognostic modelling for the formation and propagation of blistering effect are combined to form an assessment model for the evaluation of useful coating life of the multi-layered coating–substrate system and validated through experimental observation.     

An RMVT-based third-order shear deformation theory of multilayered functionally graded material plates

A Reissner mixed variational theorem (RMVT)-based third-order shear deformation theory (TSDT) is developed for the static analysis of simply-supported, multilayered functionally graded material (FGM) plates under mechanical loads. The material properties of the FGM layers are assumed to obey either the exponent-law distributions through the thickness coordinate or the power-law distributions of the volume fractions of the constituents. In this theory, Reddy’s third-order displacement model and the layerwise parabolic function distributions of transverse shear stresses are assumed in the kinematic and kinetic fields, respectively, a priori, where the effect of transverse normal stress is regarded as minor and thus ignored. The continuity conditions of both transverse shear stresses and elastic displacements at the interfaces between adjacent layers are then exactly satisfied in this RMVT-based TSDT. On the basis of RMVT, a set of Euler–Lagrange equations associated with the possible boundary conditions is derived. In conjunction with the method of variable separation and Fourier series expansion, this theory is successfully applied to the static analysis of simply-supported, multilayered FGM plates under mechanical loads. A parametric study of the effects of the material-property gradient index and the span-thickness ratio on the displacement and stress components induced in the plates is undertaken.     

Material tailoring for functionally graded hollow cylinders and spheres

We present a technique to tailor materials for functionally graded (FG) linear elastic hollow cylinders and spheres to attain through-the-thickness either a constant hoop (or circumferential) stress or a constant in-plane shear stress. The volume fractions of two phases of a FG material (FGM) are assumed to vary only with the radius and the effective material properties are estimated by using either the rule of mixtures or the Mori-Tanaka scheme; the analysis is applicable to other homogenization methods. For a FG cylinder we find the required radial variation of the volume fractions of constituents to make a linear combination of the radial and the hoop stresses uniform throughout the thickness. The through-the-thickness uniformity of the hoop stress automatically eliminates the stress concentration near the inner surface of a very thick cylinder. The through-the-thickness variations of Young’s moduli obtained with and without considering the variation of Poisson’s ratio are very close to each other for a moderately thick hollow cylinder but are quite different in a very thick hollow cylinder. For an FG sphere the required radial variation of the volume fractions of the two phases to get a constant circumferential stress is similar to that in an FG cylinder. The material tailoring results presented here should help structural engineers and material scientists optimally design hollow cylinders and spheres comprised of inhomogeneous materials.     

A model for interface cracks in layered orthotropic solids: Convergence of modal decomposition using the interaction integral method

The mode‐partitioning problem for bimaterial interfaces is still not resolved by the classical fracture mechanics approach in a satisfactory manner. Stress oscillations and overlapping crack faces are a direct consequence of the rigorous solution of the elastic boundary value problem, if the constitutive law changes discontinuously across the interface. Conversely, continuously varying material properties, also referred to as functionally graded materials (FGM), avoid these physically not admissible drawbacks. In this case the crack tip fields are of the same nature as those known from homogeneous materials. Therefore, the well‐established stress intensity factor concept can be used without any changes. Following this motivation an FGM‐interface model for delaminated composite beam structures was developed and its characteristics with respect to the modal decomposition of the crack tip fields were investigated. The considered beam structures consisted of two orthotropic layers, each of a different material. The spatial variation of the material properties in the interface region was modeled by a tanh ‐function introducing one transition parameter that controlled the FGM‐gradient. Four load cases were analyzed for each structural configuration: either a unit normal force or a unit bending moment was imposed on each end of the split beam. Thus, any load case can be simply reconstructed from the presented results by means of superposition. The stress intensity factors for modes I and II were then evaluated using an interaction integral method along with the finite element method. The corresponding results are given depending on the mesh density of the interface region, the integration domain and the transition parameter. In this manner, the influence of the transition parameter on the mode ratio and on the convergence behavior of the modal decomposition scheme with respect to its integration domain was identified. Finally, the ability of the FGM‐interface model to represent bimaterial interfaces while still maintaining the advantages of crack analysis in homogeneous materials was highlighted. Copyright © 2008 John Wiley & Sons, Ltd.     

Transient Wave Propagation in a Functionally Graded Slab and Multilayered Medium Subjected to Dynamic Loadings

In this article, the transient response in a functionally graded material (FGM) slab is analyzed by Laplace transform technique. The numerical Laplace inversion (Durbin's formula) is used to calculate the dynamic behavior of the FGM slab. The slab is subjected an uniform loading at the upper surface, and the lower surface are assumed to be traction-free or fixed conditions. The analytical solutions are presented in the transform domain and the numerical Laplace inversion is performed to obtain the transient response in time domain. To take the accuracy and computational efficiency in consideration, Durbin's method is suitable for calculating the long-time response. In addition, the FGM slab is approximated as a multilayered medium with homogeneous material in each layer, and the transient responses of FGM formulation and multilayered solution are discussed in detail.