Finite element modelling of development of stresses in thermal barrier coatings

Abstract

Thermal barrier coatings (TBCs) are used to allow higher gas temperatures (and hence greater efficiencies) in power generation gas turbines and/or to lengthen blade lifetimes, by reducing the heat transfer from the combustion gases to the blade substrate materials. However, the lives of TBC coated components tend to be limited by the growth of an oxide layer between the thermally insulating top coat and the MCrAlY coated superalloy substrate; this results in stresses which can lead to spallation (flaking-off) of the top coat. The present paper gives an overview of a recent programme of modelling work undertaken to understand the development of stresses due to the growth of the oxide layer. Typical examples of the rough interface between top coat and bond coat are characterised in terms of their aspect ratios. Representative geometries are then studied using a series of 2D finite element models of the interface layer. Initial models assumed a simple parabolic growth law for the oxide layer; the models were then developed to consider the evolving properties of the substrate and bond coat, and a more rigorous model of the oxidation process was implemented. The resulting model takes as its input the results of a microstructure evolution model developed at Loughborough University, which provides phase proportions. These in turn are used in conjunction with a constitutive model based upon an analytical homogenisation (based on Eshelby approach) that allows the substrate and bond coat creep and elastic behaviour to be predicted as the microstructure evolves. The formation of the thermally grown oxide (TGO) is modelled by considering the volume change due to oxidation. In turn, the model predicts the evolution of stresses at positions within the TGO layer. The influences of interface roughness, temperature and bond coat formulations are all explored by running the coupled model with different input parameters.     

Surface and adhesion changes of atmospheric barrier discharge-treated polypropylene in air and nitrogen

Oriented polypropylene treated by atmospheric barrier discharges in air and nitrogen was investigated using several techniques: contact angle measurements, ATR-FT-IR spectroscopy and two adhesion tests based on the stripping of an applied ink layer. The activation in an air discharge was found to be much weaker compared to the activation in industrial grade nitrogen, particularly with respect to adhesion. The adhesion was found to be much better in nitrogen in spite of the common use of air in industrial 'corona discharges'. A new 'abrasive shear-stripping' (AS) test for ink coating adhesion was designed and performed. It was shown that the AS test was much more sensitive than the classical adhesive tape test and was sensitive enough to monitor ageing and overtreatment. The contact angle measurements did not correlate completely with the adhesion properties and could not monitor the overtreatment, while the ATR-FT-IR technique indicated changes just for overtreated foils.     

Mechanical behaviour of as sprayed and sintered air plasma sprayed partially stabilised zirconia

Abstract

The mechanical behaviour of free standing air plasma sprayed (APS) partially yttria stabilised zirconia (P-YSZ) thermal barrier coatings (TBC) at room temperature and at elevated temperatures up to 1050°C have been investigated. Creep tests under constant compressive load have been conducted as well as cyclic measurements of compressive stress – strain hysteresis loops with increasing maximum load, yielding Young's moduli of the porous partially yttria stabilised zirconia. Both mechanical parameters are needed for accurate modelling of the local stress fields of, for example, airfoils to identify critical regions where damage or even failure of the component may occur. Specimens in the as sprayed and sintered state were tested. The microstructural changes caused by sintering and mechanical loading at high temperature of the thermal barrier coatings have been characterised by porosity measurements made from metallographic cross-sections.     

OpenMP Fortran程序中死锁的静态检测

与BARRIER相关的死锁是导致OpenMP程序失效的重要隐患之一.对该类隐患的静态检测有助于在OpenMP程序运行之前提高其正确性.为了便于检测,将这种死锁分为两类.借助搜索与数据流分析分别按照存在性规则和非一致性规则检测第1类和第2类死锁.扩展了传统的控制流图以表示OpenMP程序.对于每个检测到的死锁,通过回溯记录控制流图中相关的路径,并利用静态分支预测量化其严重程度.基于上述思想,实现了一个OpenMP Fortran程序中死锁的静态检测工具C-Checker.实验表明,该工具能有效地检测OpenMP程序中与BARRIER相关的死锁.     

Adhesion characteristics of plasma-surface-treated carbon fiber-epoxy composite with respect to release films used during demolding

The load capabilities of carbon fiber-epoxy composite adhesive joints are affected by surface characteristics of the composite adherends such as surface free energy and chemical composition, which can be altered by plasma surface treatment and the type of release film for demolding carbon fiber-epoxy composites from metal molds. In this paper, suitable plasma surface treatment conditions for carbon fiber-epoxy composite adherends were investigated to enhance the strength of carbon fiber-epoxy composite adhesive joints using dielectric barrier discharges of atmospheric pressure plasmas. The effects of plasma surface treatment on the surface free energy and adhesion strength of carbon fiber-epoxy composites were experimentally investigated with respect to surface treatment time. Also, the surface and adhesion characteristics of carbon fiber-epoxy composites were investigated with respect to release films such as fluorinated ethylene propylene (FEP), high density polyethylene (PE) and Nylon 6.6. Quantitative chemical bonding analysis with X-ray photoelectron spectroscopy (XPS) was also performed to understand the load capabilities of composite adhesive joints with respect to plasma treatment time and release films. From the experimental results, it was found that plasma treatment of carbon fiber-epoxy composites did enhance its adhesion strength, irrespective of the type of release film. Regarding adhesion strength, Nylon 6.6 was found to be the most suitable release film for these composites when no plasma treatment could be applied. From the XPS measurements on carbon fiber-epoxy composites, it was found that the carbon bond ratio of C=O to C-C and C-H reached a maximum at around 10 s treatment time, which corresponded well with the load transmission capability of the composite adhesive joint.     

Influence of Differently Structured Aluminium–Polypropylene Interfaces on Adhesion

Polar groups were introduced on polypropylene surfaces for increasing the surface energy and the peel strength to evaporated aluminium layers. Three kinds of plasma processes were used for introducing such functional groups to polyolefin surfaces: low-pressure radio-frequency (RF) O₂ plasma exposure, atmospheric-pressure dielectric-barrier discharge (DBD) treatment in air, and the deposition of allylamine plasma polymer. The amino groups of the allylamine plasma polymer were also used as anchoring points for chemical introduction of covalently bonded spacer molecules equipped with reactive endgroups. Thus, silanol endgroups of a covalently bonded spacer were able to interact with the evaporated metal layer. The Al–PP composites achieved a maximal peel strength of 470 N/m by exposing the polymer to the lowpressure O₂ plasma and 500 N/m on exposure to the atmospheric DBD plasma. After allylamine plasma polymerization and grafting of spacers, the peel strength was usually higher than 1500 N/m and the composites could not be peeled.     

Long Term Effects of Air Dielectric Barrier Discharge Treatment on the Surface Properties of Ethylene Vinyl Acetate (EVA)

This paper discusses the long term effects of dielectric barrier discharge (DBD) treatment on the surface properties of ethylene vinyl acetate (EVA) film. The EVA surface was characterised using contact angle measurements, X-ray photoelectron spectroscopy (XPS), atomic force microscopy (AFM), and 180° peel tests. EVA subjected to two different treatment times was compared to as-received and solvent cleaned film. The long term stability of the surface modification induced by the DBD treatment was studied over a period of 466 days. On initial application of DBD treatment to the EVA surface an increased wettability was observed, evident from a decreased water contact angle, improved peel strength when bonded, and an increased level of carbon–oxygen moieties measured using XPS. However, over the storage period of 466 days the material reverted to almost its original state with the contact angle being only ～3° lower than that of as-received EVA compared to a difference ～25° directly after treatment. AFM measurements showed that the treatment had a slight smoothing effect on the surface topography.     

Combustion synthesis and characterisation of lanthanum hexa-aluminate

Abstract

Lanthanum hexa-aluminate (LHA) is considered a promising material for thermal barrier coatings for gas turbine applications as well as oxidation resistant coatings for fibres in oxide based ceramic composites. Combustion synthesis has attractive advantages such as simple experimental setup, low cost, short reaction time, energy savings due to exothermic reaction, better control of stoichiometry and fine powder size. The present study involves combustion synthesis of LHA using lanthanum and aluminium nitrates as oxidising precursors, and urea as fuel. The precursor salts were dissolved in a minimum amount of deionised water and the solution was heated in a mantle heater to temperatures of around 300–350°C, at which combustion takes place with rapid evolution of gas. The LHA powder was also prepared by a precipitation route for comparative study. The as synthesised powders were calcined at up to 1450°C and subjected to X-ray diffraction for phase evolution studies. Product powders were then characterised. The influence of the lanthanum/aluminium molar ratio in the starting composition and the effect of temperature on the formation sequences of lanthanum monoaluminate (LMA) and LHA and on the conversion of LMA to LHA are discussed.