SpringerLink
Log in

Stochastic Simulation of Thermal Residual Stress in Environmental Barrier Coated 2.5D Woven Ceramic Matrix Composites

  • Original Research Article
  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

This article has been updated

Abstract

This paper deals with the evolution of thermal residual stress (TRS) in Ceramic Matrix Composites (CMC) with environmental barrier coating (EBC) for aeroengine applications. In particular, in hot section component applications, where the durability requirement is of primary concern, CMC/EBC materials seem to be the most fascinating solution for effective and performant design. In this work, a numerical analysis has been conducted to study the effect of TRS on the damage mechanism in the 2.5D woven CMC coated with EBC. To figure out the heterogeneous and stochastic evolution of TRS in the coatings and substrate, a micromechanical finite element model of the composites containing the coatings was established based on the concept of representative volume elements. Especially, the variation of microstructure characteristics and constituents properties were taken into account in the micromechanical model. A series of simulations were performed to investigate the evolution of TRS during the cooling process after preparation and the thermo-mechanical loading process. Then, the thermal stress in coatings and substrate was calculated, and the influence mechanism of TRS on the failure was analyzed by comparison. The driven mechanism of the delamination crack and vertical crack was discussed based on the TRS results with uncertain characteristics. Based on this, uncertainty quantification can be performed to predict the durability life of the CMC/EBC system.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price includes VAT (United Kingdom)

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

Change history

  • 10 March 2024

    An note concerning the article’s inclusion in a special topic issue has been added since the article was originally published.

Reference

  1. B.T. Richards, S. Sehr, F. de Franqueville et al., FRACTURE MECHANISms of Ytterbium Monosilicate Environmental Barrier Coatings During Cyclic Thermal Exposure, Acta Mater., 2016, 103(1), p 448–460.

    CAS  Google Scholar 

  2. N.N. Nemeth, S.K. Mital, E.J. Pineda et al., Stochastic Simulation of Mudcrack Damage Formation in an Environmental Barrier Coating, NASA/TP—2020-220185 (R), NASA, Washington, 2020.

    Google Scholar 

  3. S.K. Mital, S.M. Arnold, T.M. Ricks et al., Influence of Thermally-Grown Oxide (TGO) Layer on the Driving Forces Associated with Failure in Environmental Barrier Coating (EBC) Systems, GRC-E-DAA-TN76639 (R), NASA, Washington, 2020.

    Google Scholar 

  4. L. Wang, Y. Wang, X.G. Sun et al., Finite Element Simulation of Residual Stress of Double-Ceramic-Layer La2Zr2O7/8YSZ Thermal Barrier Coatings Using Birth and Death Element Technique, Comput. Mater. Sci., 2012, 53(1), p 117–127.

    CAS  Google Scholar 

  5. Q.M. Yu, L. Cen and Y. Wang, Numerical Study of Residual Stress and Crack Nucleation in Thermal Barrier Coating System with Plane Model, Ceram. Int., 2018, 44(5), p 5116–5123.

    CAS  Google Scholar 

  6. O. Sarikaya, E. Celik, S.C. Okumus et al., Effect on Residual Stresses in Plasma Sprayed Al-Si/B 4C Composite Coatings Subjected to Thermal Shock, Surf. Coat. Technol., 2005, 200(7), p 2497–2503.

    CAS  Google Scholar 

  7. J. Li, E. Martin, D. Leguillon et al., A Finite Fracture Model for the Analysis of Multi-Cracking in Woven Ceramic Matrix Composites, Compos. Part B-eng., 2018, 139, p 75–83.

    CAS  Google Scholar 

  8. X. Dong and Y.C. Shin, Predictions of Thermal Conductivity and Degradation of Irradiated SiC/SiC Composites by Materials-Genome-Based Multiscale Modeling, J. Nucl. Mater., 2018, 512, p 268–275.

    CAS  Google Scholar 

  9. G. Fang, X. Gao and Y. Song, Finite Element Simulation of Stress Transfer Through the Mul-Tilayer Interphase in Ceramic Matrix Composites, Acta Mater. Compos. Sinica, 2018, 35(12), p 3415–3422.

    Google Scholar 

  10. Y. Song, X. Gao and Z. Sun, Progress on Fatigue Hysteresis Mechanisms and Models of Aero-Engine Ceramic Matrix Composites, J. Nanj. Univ. Aeronaut. Astronaut., 2019, 51(4), p 417–426.

    Google Scholar 

  11. X. Zhang, K. Zhou, M. Liu et al., Preparation of Si/Mullite/Yb2SiO5 Environment Barrier Coating (EBC) by Plasma Spray-Physical Vapor Deposition (PS-PVD), J. Inorgan. Mater., 2018, 33(3), p 325–330.

    Google Scholar 

  12. Q. Liu, S. Huang, A. He et al., Research Progress in Environmental Barrier Coatings of SIC Ceramic Matrix Composites, J. Mater. Eng., 2018, 46(10), p 1–8.

    Google Scholar 

  13. J. Xu, V.K. Sarin, S. Dixit et al., Stability of Interfaces in Hybrid EBC/TBC Coatings for Si-Based Ceramics in Corrosive Environments, Int. J. Refract Metal Hard Mater., 2015, 49(3), p 339–349.

    CAS  Google Scholar 

  14. K. Lee, M.V. Roode, T. Kashyap et al., Environmental Barrier Coatings for Ceramic Matrix Composites-an Overview, GRC-E-DAA-TN38835 (R), NASA, Washington, 2017.

    Google Scholar 

  15. A. Bhattacharyya and D. Maurice, Residual Stresses in Functionally Graded Thermal Barrier Coatings, Mech. Mater., 2019, 129(1), p 50–56.

    Google Scholar 

  16. N. Al Nasiri, N. Patra, M. Pezoldt et al., Investigation of a Single-Layer EBC Deposited on SiC/SiC CMCs: Processing and Corrosion Behaviour in High-Temperature Steam, J. Eur. Ceramic Soc., 2019, 39(8), p 2703–2711.

    CAS  Google Scholar 

  17. M.P. Appleby, D. Zhu and G.N. Morscher, Mechanical Properties and Real-Time Damage Evaluations of Environmental Barrier Coated SiC/SiC CMCs Subjected to Tensile Loading Under Thermal Gradients, Surf. Coat. Technol., 2015, 284(12), p 318–326.

    CAS  Google Scholar 

  18. K.N. Lee, J.I. Eldridge and R.C. Robinson, Residual Stresses and their Effects on the Durability of Environmental Barrier Coatings for SIC Ceramics, J. Am. Ceram. Soc., 2005, 88(12), p 3483–3488.

    CAS  Google Scholar 

  19. A. Abdul-Aziz and R.T. Bhatt, Modeling of Thermal Residual Stress in Environmental Barrier Coated Fiber Reinforced Ceramic Matrix Composites, J. Compos. Mater., 2012, 46(10), p 1211–1218.

    CAS  Google Scholar 

  20. C.M. Heveran, J. Xu, V.K. Sarin et al., Simulation of Stresses in TBC-EBC Coating Systems for Ceramic Components in Gas Turbines, Surf. Coat. Technol., 2013, 235(11), p 354–360.

    CAS  Google Scholar 

  21. P. Meyer and A.M. Waas, Mesh-Objective Two-Scale Finite Element Analysis of Damage and Failure in Ceramic Matrix Composites, Integr. Mater. Manufact. Innov., 2015, 4(1), p 1–18.

    Google Scholar 

  22. M. Braginsky and C.P. Przybyla, Simulation of Crack Propagation/Deflection in Ceramic Matrix Continuous Fiber Reinforced Composites with Weak Interphase Via the Extended Finite Element Method, Compos. Struct., 2016, 136, p 538–545.

    Google Scholar 

  23. J. Kabel, Y. Yang, M. Balooch et al., Micro-Mechanical Evaluation of SiC-SiC Composite Interphase Properties and Debond Mechanisms, Compos. Part B Eng., 2017, 131, p 173.

    CAS  Google Scholar 

  24. Y. Xu and T. You, Minimizing Thermal Residual Stresses in Ceramic Matrix Composites by using Iterative Mapreduce Guided Particle Swarm Optimization Algorithm, Compos. Struct., 2013, 99(5), p 388–396.

    Google Scholar 

  25. C.H. Hsueh and E.R. Fuller Jr., Residual Stresses in Thermal Barrier Coatings: Effects of Interface Asperity Curvature/Height and Oxide Thickness, Mater. Sci. Eng. A, 2000, 283(1–2), p 46–55.

    Google Scholar 

  26. X. Gao, X. Han and Y. Song, X-ray Computed Tomography based Microstructure Reconstruction and Numerical Estimation of Thermal Conductivity of 2.5d Ceramic Matrix Composite, Ceram. Int., 2017, 43(13), p 9790–9797.

    CAS  Google Scholar 

  27. S.K. Mital, R.K. Goldberg and P.J. Bonacuse, Two-Dimensional Nonlinear Finite Element Analysis of cmc Microstructures, NASA/TM-2012-217297(R), NASA, Washington, 2012.

    Google Scholar 

  28. Z. Sun, C. Wang, X. Niu et al., A Response Surface Approach for Reliability Analysis of 2.5d c/sic Composites Turbine Blade, Compos. Part B Eng., 2016, 85(2), p 277–285.

    CAS  Google Scholar 

  29. B.J. Harder, J.D. Almer et al., Residual Stress Analysis of Multilayer Environmental Barrier Coatings, J. Am. Ceram. Soc., 2009, 92(2), p 452–459.

    CAS  Google Scholar 

  30. K.N. Lee, D.S. Fox and N.P. Bansal, Rare Earth Silicate Environmental Barrier Coatings for SiC/SiC Composites and Si3N4 Ceramics, J. Eur. Ceram. Soc., 2005, 25(10), p 1705–1715.

    CAS  Google Scholar 

Download references

Acknowledgments

This work was supported by the National Science and Technology Major Project (grant numbers Y2019-I-0018-0017).

Author information

Authors and Affiliations

  1. College of General Aviation and Flight, Nan**g University of Aeronautics and Astronautics, Liyang, 213300, Jiangsu, China

    Fang Guangwu

  2. Jiangsu Province Key Laboratory of Aerospace Power System, Nan**g University of Aeronautics and Astronautics, Nan**g, 210016, China

    Fang Guangwu, Zheng Mingwei, Chen Mingzhu, Gao **guang & Song Yingdong

  3. Key Laboratory of Aero-engine Thermal Environment and Structure, Ministry of Industry and Information Technology, Nan**g University of Aeronautics and Astronautics, Nan**g, 210016, China

    Fang Guangwu, Zheng Mingwei, Chen Mingzhu, Gao **guang & Song Yingdong

Authors
  1. Fang Guangwu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zheng Mingwei
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Chen Mingzhu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Gao **guang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Song Yingdong
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Fang Guangwu.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

This invited article is part of a special topical issue of the Journal of Materials Engineering and Performance on Residual Stress Analysis: Measurement, Effects, and Control. The issue was organized by Rajan Bhambroo, Tenneco, Inc.; Lesley Frame, University of Connecticut; Andrew Payzant, Oak Ridge National Laboratory; and James Pineault, Proto Manufacturing on behalf of the ASM Residual Stress Technical Committee.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Guangwu, F., Mingwei, Z., Mingzhu, C. et al. Stochastic Simulation of Thermal Residual Stress in Environmental Barrier Coated 2.5D Woven Ceramic Matrix Composites. J. of Materi Eng and Perform 33, 4114–4123 (2024). https://doi.org/10.1007/s11665-024-09244-6

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-024-09244-6

Keywords

Search

Navigation