虚拟裂纹闭合技术在热障涂层裂纹扩展中的研究进展

李帅; 何扬; 彭慧璇; 任继华; 蔡厚道; 周启兴

doi:10.16490/j.cnki.issn.1001-3660.2025.13.003

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表面技术 ›› 2025, Vol. 54 ›› Issue (13) : 29-42. DOI: 10.16490/j.cnki.issn.1001-3660.2025.13.003

研究综述

虚拟裂纹闭合技术在热障涂层裂纹扩展中的研究进展

李帅, 何扬, 彭慧璇, 任继华^*, 蔡厚道, 周启兴

作者信息 +

Research Progress of Virtual Crack Closure Technology in Crack Propagation of Thermal Barrier Coatings

LI Shuai, HE Yang, PENG Huixuan, REN Jihua^*, CAI Houdao, ZHOU Qixing

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文章历史 +

摘要

热障涂层因其优异的抗氧化、隔热、耐腐蚀性能以及结构简单的特点,被广泛应用于航空发动机等高温热端部件表面。在复杂的服役环境中,涂层的失效通常由裂纹扩展引起。针对裂纹扩展问题,最有效的方法是通过数值模拟对损伤过程进行仿真,从而再现裂纹扩展过程,预测裂纹扩展趋势及寿命。其中,虚拟裂纹闭合技术（Virtual Crack Closure Technique,VCCT）因其只需对热障涂层进行一次完整分析即可获得变形,且无需奇异单元的优点,被广泛应用于裂纹扩展研究。本文系统梳理了VCCT理论的发展及其在热障涂层研究中的应用进展。首先介绍了裂纹扩展的研究现状,随后重点综述了针对裂纹扩展的数值模拟方法,特别是VCCT的基本原理及其在模拟中的拓展。最后,从能量释放率和断裂准则两方面阐述了虚拟裂纹闭合技术在热障涂层裂纹扩展中的研究进展。未来,应发展多裂纹交互精细化建模方法,结合人工智能技术构建数据驱动模型,通过残差神经网络（Residual Neural Network,ResNet）与生成对抗网络（Generative Admissible Network,GAN）实现应力场与约束的模型重构,从而实现裂纹扩展的评估与寿命预测,推动涂层失效分析从离线仿真向实时预测转型。

Abstract

Thermal barrier coatings are extensively utilized on the surfaces of high-temperature hot-end components, such as aero-engines, due to their excellent antioxidant, heat-insulating, and corrosion-resistant properties, as well as their simple structure. In complex service environments, coating failures are often attributed to crack propagation. Generally, three methods are employed to study crack propagation in thermal barrier coatings: analytical methods, experimental tests, and numerical simulations. For crack propagation in coatings, the most effective approach involves conducting numerical simulations of the damage process. Among these, the VCCT is widely used for its advantages, such as calculating the strain energy release rate using nodal forces and displacements, and obtaining deformation through a single comprehensive analysis of the thermal barrier coating without the need for singular elements.
This paper primarily discusses the research progress of applying the virtual crack closure technique to interface crack propagation in thermal barrier coatings. In the first chapter, research on crack propagation is introduced. The findings indicate that pre-fabricating vertical cracks in the bonding layer and altering the roughness of the bonding layer can enhance surface crack propagation. Additionally, rationally designing the ceramic layer structure and selecting an appropriate substrate can improve interface crack propagation. In the second chapter, common numerical simulation methods for crack propagation are presented. Currently, the primary numerical simulation methods for exploring cracks include the Cohesive Zone Model (CZM), the Extended Finite Element Method (XFEM), and the VCCT. Advantages of the VCCT are as follows: 1. It is not sensitive to the size of the finite-element mesh; 2. It can yield good results with a coarse mesh; 3. It does not require excessive additional efforts in mesh preparation. Subsequently, the fundamental principle of the virtual crack closure technique and its application in simulations are described. Since the VCCT principle is based on the concept that the required energy equals the work done in closing a crack, it is highly suitable for calculating the energy release rate during the crack propagation process. Therefore, in the third chapter, the research progress of the virtual crack closure technique in crack propagation of thermal barrier coatings is discussed in terms of energy release rate and fracture criterion. Additionally, the simulation method is summarized and its future prospects for crack propagation issues in thermal barrier coatings are outlined.
In conclusion, the virtual crack closure technique has been demonstrated to be a valuable tool for investigating interface crack propagation in thermal barrier coatings. Compared with traditional analytical and experimental methods, this technique can accurately simulate the crack propagation process and calculate key parameters such as the energy release rate and fracture criterion, offering significant advantages. In the future, it will be essential to develop a fine modeling method for multi-crack interactions, establish a data-driven model integrated with artificial intelligence technology, and reconstruct the stress field and constraint model using residual neural networks (ResNet) and generative admissible networks (GAN). This will facilitate the evaluation and lifetime analysis of crack propagation and promote the transition of coating failure analyses from offline simulation to real-time prediction.

导出引用

李帅, 何扬, 彭慧璇, 任继华, 蔡厚道, 周启兴. 虚拟裂纹闭合技术在热障涂层裂纹扩展中的研究进展[J]. 表面技术. 2025, 54(13): 29-42 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.13.003

LI Shuai, HE Yang, PENG Huixuan, REN Jihua, CAI Houdao, ZHOU Qixing. Research Progress of Virtual Crack Closure Technology in Crack Propagation of Thermal Barrier Coatings[J]. Surface Technology. 2025, 54(13): 29-42 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.13.003

中图分类号： TG174

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