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.
Key words
thermal barrier coatings /
porosity /
aspect ratio /
pore orientation /
pore size /
residual stress /
simulation
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Funding
China Postdoctoral Science Foundation (2021M691341); Shanghai Technical Institute of Electronics & Information Research Foundation (KYPT-2023-23)
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