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

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

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

Research Review

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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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.

Key words

thermal barrier coating / virtual crack closure technology / crack propagation / strain energy release rate / fracture criterion

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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

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