Thermal Analysis of Turbine Blades with Thermal Barrier Coatings Using Virtual Wall Thickness Method

Avirtual wall thicknessmethod is developed to simulate the temperature field of turbine bladeswith thermal barrier coatings(TBCs),to simplify the modeling process and improve the calculation efficiency.The results show that the virtualwall thickness method can improve themesh quality by 20%,reduce the number ofmeshes by 76.7%and save the calculation time by 35.5%,compared with the traditional real wall thickness method.The average calculation error of the two methods is between 0.21%and 0.93%.Furthermore,the temperature at the blade leading edge is the highest and the average temperature of the blade pressure surface is higher than that of the suction surface under a certain service condition.The blade surface temperature presents a high temperature at both ends and a low temperature in themiddle height when the temperature of incoming gas is uniformand constant.The thermal insulation effect of TBCs is the worst near the air film hole,and the best at the blade leading edge.According to the calculated temperature field of the substrate-coating system,the highest thermal insulation temperature of the TC layer is 172.01 K,and the thermal insulation proportions of TC,TGO and BC are 93.55%,1.54%and 4.91%,respectively.

Experimental and numerical investigation on the thermal and mechanical behaviours of thermal barrier coatings exposed to CMAS corrosion

Calcium-magnesium-alumino-silicate(CMAS)corrosion is a critical factor which causes the failure of thermal barrier coating(TBC).CMAS attack significantly alters the temperature and stress fields in TBC,resulting in their delamination or spallation.In this work,the evolution process of TBC prepared by suspension plasma spraying(SPS)under CMAS attack is investigated.The CMAS corrosion leads to the formation of the reaction layer and subsequent bending of TBC.Based on the observations,a corrosion model is proposed to describe the generation and evolution of the reaction layer and bending of TBC.Then,numerical simulations are performed to investigate the corrosion process of free-standing TBC and the complete TBC system under CMAS attack.The corrosion model constructs a bridge for connecting two numerical models.The results show that the CMAS corrosion has a significant influence on the stress field,such as the peak stress,whereas it has little influence on the steady-state temperature field.The peak of stress increases with holding time,which increases the risk of the rupture of TBC.The Mises stress increases nonlinearly along the thick direction of the reaction layer.Furthermore,in the traditional failure zone,such as the interface of the top coat and bond coat,the stress obviously changes during CMAS corrosion.

Microstructure and high-temperature oxidation behavior of plasma-sprayed Si/Yb2SiO5 environmental barrier coatings

An environmental barrier coating(EBC) consisting of a silicon bond coat and an Yb2-SiO5 top-coat was sprayed on a carbon fibers reinforced SiC ceramic matrix composite(CMC) by atmospheric plasma spray(APS). The microstructure of the coating annealed at 1300 ℃ and its high-temperature oxidation behavior at 1350 ℃ were investigated. The significant mass loss of silica during the plasma spray process led to the formation of Yb2SiO5 and Yb2O3 binary phases in the top-coat. Eutectics of Yb2SiO5 and Yb2O3 were precipitated in the top-coat, and channel cracks were formed in the top-coat after 20 h annealing because of the mismatch between the coefficients of thermal expansion(CTEs) of Yb2SiO5 and the SiC substrate. The EBC effectively improved the oxidation resistance of the CMC substrate. The channel cracks in the Yb2SiO5 top-coat provided inward diffusion channels for oxygen and led to the formation of oxidation delamination cracks in the bond coat, finally resulting in spallation failure of the coating after 80 h oxidation.