目的 研究热循环过程双陶瓷热障涂层YSZ/TGO界面残余应力受涂层孔隙率和孔隙形貌等的影响,为热障涂层的失效研究提供理论依据。方法 基于Python参数化建模和Abaqus有限元仿真,获得温度变化过程YSZ和热生长氧化层TGO界面上不同位置沿X轴和Y轴方向的残余应力。通过固定三变量调节单变量的方法,研究单一孔隙变量对YSZ/TGO界面残余应力的影响。结果 仅改变孔隙率时,YSZ/TGO界面左右两侧波峰的S11在孔隙率15%时取得最大拉应力,分别为16.4 MPa和22.4 MPa。左侧波峰、波谷位置的S22在15%与20%孔隙率下均具有相近的S22值,分别为90.0 MPa和12.2 MPa;仅改变长轴尺寸,左侧波峰在长轴尺寸为2.5 µm时具有最大的S22压应力85.3 MPa,此时右侧波峰具有最大S22拉应力36.4 MPa,而波谷则具有最小的S22压应力15.0 MPa;仅改变孔隙方向,90°孔隙方向在降温结束时具有最大的S11压应力22.1 MPa,而在降温开始阶段具有最大的S22拉应力33.8 MPa;仅改变纵横比,降到室温时左侧波峰S22压应力最大值98.8 MPa和右侧波峰S22拉应力最大值34.0 MPa均在纵横比4.5时出现,波谷的S22压应力在纵横比为4.5时出现最小值11.4 MPa。结论 不同孔隙率、纵横比和孔隙方向对YSZ/TGO界面的残余应力具有较大的影响,单一孔隙尺寸的变化对界面上的S11和S22影响相对较小,通过控制涂层中的孔隙率和孔隙形貌,可以降低热障涂层的失效风险。
Abstract
The work aims to investigate the effect of porosity and pore morphology (including aspect ratio, size, and orientation) on the residual stress at the Yttria-Stabilized Zirconia (YSZ) and Thermally Grown Oxide (TGO) interface within double-ceramic thermal barrier coatings (TBCs) during thermal cycling, so as to provide a theoretical basis for understanding TBC failure mechanisms.
Parametric geometric models of the double-ceramic layers with controlled elliptical pores were generated via Python scripts. Finite element simulations were performed in Abaqus to obtain the residual stress of S11 and S22 components along the X and Y directions at various locations at the YSZ/TGO interface during temperature changes. Porosity varied at 0%, 5%, 10%, 15%, and 20%. Pore aspect ratios were set to 1.0, 1.5, 3.0, and 4.5. Elliptical pore major axis sizes were selected as 2.5 µm, 5.0 µm, 7.5 µm, and 10.0 µm, and major axis orientations at 0°, 45°, 90°, and 135°. The effect of individual pore parameters on interfacial residual stresses was isolated by systematically varying one parameter while holding the other three constants.
The parametric study revealed significant dependencies of interfacial residual stresses on pore characteristics. When porosity varied from 0% to 20% (with pore orientation fixed at 0°, aspect ratio at 3.0, and major axis length at 7.5 µm), the S11 tensile stress peaks at the left and right interface regions reached maximum values of 16.4 MPa and 22.4 MPa, respectively, at 15% porosity. Conversely, the interfacial trough exhibited its maximum S11 compressive stress (17.3 MPa) at 0% porosity. Comparable S22 stresses were observed at both 15% and 20% porosity at the left peak (90.0 MPa) and trough (12.2 MPa). Under pore size variations (major axis dimensions: 2.5, 5.0, 7.5, 10.0 µm, with porosity fixed at 10%, aspect ratio at 3.0, orientation at 0°), a pore size of 2.5 µm generated the largest S22 compressive stress (85.3 MPa) at the left peak, concurrently producing the maximum S22 tensile stress at the right peak (36.4 MPa) and the lowest S22 compressive stress in the trough (15.0 MPa). At varying pore orientations (0°, 45°, 90°, 135°, with major axis length at 7.5 µm, porosity at 10%, aspect ratio at 4.5), 90° oriented pores yielded the highest S11 compressive stress (22.1 MPa) at cooling termination and the maximum S22 tensile stress (33.8 MPa) during initial cooling. For aspect ratio variations among 1.0 (circular pores), 1.5, 3.0, 4.5, with major axis length at 7.5 µm, porosity at 15%, orientation at 0°, an aspect ratio of 4.5 simultaneously produced peak values at room temperature: maximum S22 compressive stress at the left peak (98.8 MPa), maximum S22 tensile stress at the right peak (34.0 MPa), and minimum S22 compressive stress in the trough (11.4 MPa).
In conclusion, porosity, aspect ratio, and orientation significantly impact the residual stresses S11 and S22 at the YSZ/TGO interface. In contrast, variations in pore size alone exhibit a comparatively minor effect. These findings suggest that controlling coating porosity and pore morphology can be an effective strategy to reduce the risk of TBC failure.
关键词
热障涂层 /
孔隙率 /
纵横比 /
孔隙方向 /
孔隙尺寸 /
残余应力 /
仿真
Key words
thermal barrier coatings /
porosity /
aspect ratio /
pore orientation /
pore size /
residual stress /
simulation
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基金
中国博士后科学基金（2021M691341）; 上海电子信息职业技术学院科研基金（KYPT-2023-23）
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