MS3L_12386:Tue:1120:219
XXI International Congress of Theoretical and Applied Mechanics
Warsaw, Poland, August 15-21, 2004

An Analytical Model of Oxide Rumpling as the Mechanism Leading to Failure in Thermal Barrier Coatings

Daniel S. Balint (1), John W. Hutchinson (2)
1. Cambridge University, Cambridge, UK
2. Harvard University, Cambridge, USA


Thermal barrier coatings are deposited on superalloy turbine blades to protect them from engine temperatures in excess of 1000C. Failure of these multi-layer coatings is known to involve undulations that develop in the oxide layer, between the ceramic top-coat and the metallic bond-coat. At temperatures above 600C, the bond-coat creeps readily under stress. Thermal mismatch with the superalloy substrate and, for PtNiAl bond-coats, a reversible phase transformation accompanied by a change in volume, give rise to a large equi-biaxial stress in the bond-coat that dramatically reduces its ability to resist transverse deformation at elevated temperatures. The nonlinear interaction between the stress in the bond-coat and the tractions applied at the surface of the bond-coat by the compressed, undulating oxide film allows an increment of undulation growth to occur each thermal cycle. An analysis of oxide rumpling and the resultant cracking in the top-coat that leads to failure will be presented.



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