Research Progress in the Failure Behavior onthe Interface of Thermal Barrier Coatings

This paper mainly introduces the research progress on interface failure behavior in high-temperature alloy surface thermal barrier coating systems.The degradation failure and structural evolution behavior during high-temperature service were analyzed for the matrix/bonding layer interface,bonding layer/TGO interface,and TGO/ceramic layer interface in thermal barrier coatings.The research focus and direction that affect the interface performance of thermal barrier coatings were proposed.

Reliability assessment on interfacial failure of thermal barrier coatings

Thermal barrier coatings（TBCs） usually exhibit an uncertain lifetime owing to their scattering mechanical properties and severe service conditions. To consider these uncertainties, a reliability assessment method is proposed based on failure probability analysis. First, a limit state equation is established to demarcate the boundary between failure and safe regions, and then the failure probability is calculated by the integration of a probability density function in the failure area according to the first- or second-order moment.It is shown that the parameters related to interfacial failure follow a Weibull distribution in two types of TBC. The interfacial failure of TBCs is significantly affected by the thermal mismatch of material properties and the temperature drop in service.

Failure analysis with a focus on thermal aspect towards developing safer Na-ion batteries

Safety requirements stimulate Na-based batteries to evolve from high-temperature Na–S batteries to room-temperature Na-ion batteries(NIBs).Even so,NIBs may still cause thermal runaway due to the external unexpected accidents and internal high activity of electrodes or electrolytes,which has not been comprehensively summarized yet.In this review,we summarize the significant advances about the failure mechanisms and related strategies to build safer NIBs from the selection of electrodes,electrolytes and the construction of electrode/electrolyte interfaces.Considering the safety risk,the thermal behaviors are emphasized which will deepen the understanding of thermal stability of different NIBs and accelerate the exploitation of safe NIBs.

Failure of EB-PVD Thermal Barrier Coatings Subjected to Thermo-Mechanical Loading

Thermal barrier coatings （TBCs） were developed to protect metallic blades and vanes working in turbo-engines. The two-layered structure TBCs, consisting of NiCoCrAlY bond coat and yttria stabilized zirconia （YSZ）, were deposited on a cylinder of superalloy substrate by the electron beam-physical vapor deposition （EB-PVD）. The failure mechanism of the TBCs was investigated with a thermo-mechanical fatigue testing system under the service condition similar to that for turbine blades. Non-destructive evaluation of the coated specimens was conducted through the impedance spectroscopy. It is found that the crack initiation mainly takes place on the top coat at the edge of the heated zones.

Characterization of Failure Mechanisms of Duplex and Graded Thermal Barrier Coatings Exposed to Thermal Shock Test

The beginning of failure of a (ZrO2-7%Y2O3)/(Ni-22%Co-17%Cr-12.5%Al-0.6%Y) duplex andgraded coating systems on lnconel 617 and IN738LC in burner rig tests has been characterized.The test conditions are 40 s heating up to 75O℃ substrate temperature followed by 80 s aircooling. Failure is considered at the appearance of the first bright spot during heating period.Stresses due to thermal expansion mismatch strains on cooling are the probable cause of life-limiting in this conditions of testing.

Finite element model analysis of thermal failure in connector

Thermal analysis and thermal diagnose are important for small power connector especially in electronic devices since their structure is usually compact. In this paper thermal behavior of small power connector was investigated. It was found that the contact resistance increased due to the Joule heating, and that increased contact resistance produced more Joule heating; this mutual action causes the connector to lose efficiency. The thermal distribution in the connector was analyzed using finite element method (FEM). The failure mechanism is discussed. It provides basis for improving the structure. The conclusion was verified by experimental results.

Initiation of vacuum breakdown and failure mechanism of the carbon nanotube during thermal field emission

The carbon nanotube （CNT）-based materials can be used as vacuum device cathodes. Owing to the excellent field emission properties of CNT, it has great potentials in the applications of an explosive field emission cathode. The falling off of CNT from the substrate, which frequently appears in experiments, restricts its application. In addition, the onset time of vacuum breakdown limits the performance of the high-power explosive-emission-cathode-based diode. In this paper, the characteristics of the CNT, electric field strength, contact resistance and the kind of substrate material are varied to study the parameter effects on the onset time of vacuum breakdown and failure mechanism of the CNT by using the finite element method.

INFRARED THERMAL IMAGE STUDY ON THE FOREWARNING OF COAL AND SANDSTONE FAILURE UNDER LOAD

In the experimental study, AGE-782 thermal instrument was used to detect the infrared radiation variation of coal and sandstone (wave-length range 3.6～5.5 μm was used). It's discovered that coal and sandstone failure under load have three kinds of infrared thermal features as well as infrared forewarning messages. That are: (1) temperature rises gradually but drops before failure ; (2) temperature rises gradually but quickly rises before failure; (3) first rises,then drops and lower temperature emerges before failure. The further researches and the prospect of micro-wave remote sensing detection .on ground pressure is also discussed.

Tribological Properties and Failure Analysis of PTFE Composites used for Seals in the Transmission Unit

The sealing rings are one of the most important components as the sealing devices in the wet clutch unit of a heavy vehicle. The sealing ring, made from PTFE composites, was subjected to serious wear on the sealing surface, but the mating metal surface only had slight abrasion. A specialized test rig was designed for wear research and failure analysis of the sealing ring. The composition analyses of the ring material, working conditions and wear surface characteristics by visual inspection and tribological properties as well as microscopic analysis with scanning electron microscope was performed to determine the wear mechanism and failure causes. Results revealed that the wear of PTFE composites was characterized by abrasion and adhesion after a certain duration testing, and the wear mechanism changed to thermal fatigue and abrasive wear in the stage of intense wear. The thermal deformation and fatigue were primarily responsible for the rapid wear of the PTFE composites for the sealing rings.

Peridynamic modeling and simulation of thermo-mechanical de-icing process with modified ice failure criterion

De-icing technology has become an increasingly important subject in numerous applications in recent years.However,the direct numerical modeling and simulation the physical process of thermomechanical deicing is limited.This work is focusing on developing a numerical model and tool to direct simulate the de-icing process in the framework of the coupled thermo-mechanical peridynamics theory.Here,we adopted the fully coupled thermo-mechanical bond-based peridynamics(TM-BB-PD)method for modeling and simulation of de-icing.Within the framework of TM-BB-PD,the ice constitutive model is established by considering the influence of the temperature difference between two material points,and a modified failure criteria is proposed,which takes into account temperature effect to predict the damage of quasi-brittle ice material.Moreover,thermal boundary condition is used to simulate the thermal load in the de-icing process.By comparing with the experimental results and the previous reported finite element modeling,our numerical model shows good agreement with the previous predictions.Based on the numerical results,we find that the developed method can not only predict crack initiation and propagation in the ice,but also predict the temperature distribution and heat conduction during the de-icing process.Furthermore,the influence of the temperature for the ice crack growth pattern is discussed accordingly.In conclusion,the coupled thermal-mechanical peridynamics formulation with modified failure criterion is capable of providing a modeling tool for engineering applications of de-icing technology.

Electric Current-induced Failure of 200-nm-thick Gold Interconnects

200-nm-thick Au interconnects on a quartz substrate were tested in-situ inside a dual-beam microscope by applying direct current, alternating current and alternating current with a small direct current component. The failure behavior of the Au interconnects under three kinds of electric currents were characterized in-situ by scanning electron microscopy. It is found that the formation of voids and subsequent growth perpendicular to the interconnect direction is the fatal failure mode for all the Au interconnects under three kinds of electric currents. The failure mechanism of the ultrathin metal lines induced by the electric currents was analyzed.

Failure analysis of a kind of low power connector

A kind of low power connector used e.g. in household appliances was partly burned in routine experiment. The heat sources were four paralleled contacts constructed by springs (Sn/CuSn-alloy) in socket and a plug sheet (Ni/Steel) while mating. The contact interfaces were detected by scanning electronic microscope (SEM) and X-ray energy dispersive spectros- copy (XEDS), obvious wear tracks and various contaminants, including element Si, Al, Na, K, S, Cl, O, etc., were found. The contamination degrees on the four paralleled contacts were different, so that the ratio of average contact resistance on the four contacts was about 5:8:3:1. The maximum contact resistance on contacts of the plug sheet reached 28 ?. The main failure rea- sons were fretting and contamination between the contact interfaces. Fretting simulation showed that connection resistance of connectors was raised up, even to ohms level. When the current increased to 5 A, the socket housing was heated and decom- posed. By the thermal analysis, it was estimated that the connector would be burned under the lower current if the current was not evenly distributed on the four paralleled contacts caused by uneven contamination. Improvement methods for connector failure are also discussed.

Cause for Exit Failure of End Mill

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FAILURES AND THE LIFE OF FURNACE TUBES

It is showed after the furnace tubes serviced for 8-10 years that the density of damage in the HAZ (heat affected zone) of the weld has higher than in parent metals, though the depth of damage is not equal to. By the test of creep crack growth, it is also acquired that under same mechanic parameter C* (t), the rate of creep crack growth in the HAZ is more than twice as fast as in parent metals. Two mechanisms (overheating and thermal shock) of failure occurred in an accident are presented. The stress of thermal shock is analyzed, in which the change of the elasticity modulus with the radius ET = /(r) is considered. Based on it, the safety region of the thermal shock is obtained. Finally, two sets of curves for the safe life are suggested which can facilitate to estimate the remaining life of HK-40 or HP-Nb tubes by their creep rupture data.

Failure Stress Energy Formula

Goal: In the process of exploitation of ceramic composites often we encounter not only high mechanical stresses but also thermal loads and air-thermal shocks. These loads are transformed into failure/rupture stress energy, when strength of work-pieces is less than loads, which develops pluck from the crack top, resulting in destruction of objects. Considering such extreme operation conditions computation of energies which contribute to materials catastrophe seems rather interesting. Method: The formula parameters were selected on the basis of study and generalization of micro- and macro-mechanical characteristics of ceramic materials. Results: The formula covers the process of creation of energies as a result of mechanical and thermal loads affecting the work-piece and analyses of mechanisms of impact of these energies on the cracks existing in the material;results of energies affecting the existing cracks as a result of such loads and results of starting of mechanisms of spreading of energies developed inside the work piece, which lead material to the catastrophe. Conclusion: On the basis of crack development mechanisms the universal relationship of total energy of the work-piece and its mass was established considering crack developing speed under critical stress conditions. Failure stress energy formula has been offered.

Effect of heating-rate on failure temperature of pre-loaded magnesium alloy

The response and failure of magnesium alloy AZ31 specimens subjected to different pre-loaded-stress levels and heating rates were investigated with a Gleeble-1500 thermo-mechanical material testing system.It is found that the increases of either pre-loaded stresses or heating-rates decrease the failure temperatures of the specimens.The metallographs of the tested specimens were also observed.It is shown that the high heating-rate may cause stronger local thermal inconsistency,which remarkably increases the microdefects and reduces the macroscopic mechanical properties of the material.

Toughness Effect of Graphene Oxide-Nano Silica on Thermal-Mechanical Performance of Epoxy Resin

A graphene oxide/nano-silica(GOS)hybrid was rapidly and easily synthesized using graphene oxide(GO)and nano-silica(nano-SiO_(2))as raw materials,and the synthesized GOS was used to improve the mechanical properties of epoxy resin(EP).The modified EP with different mass fractions of GOS(0,0.1%,0.2%,0.3%and 0.4%)were prepared and studied.The structure,thermal stability,mechanical properties,fracture toughness and failure morphology of the modified EP were analyzed.The results showed that the tensile strength of GOS modified EP increased from 40.6 MPa to 80.2 MPa compared with EP,the critical stress intensity factor of GOS modified EP increased by 65.9%from 0.82 MPa·m^(1/2)to 1.36 MPa·m^(1/2),indicating a significant enhancement in fracture toughness.In addition,failure morphology was observed by scanning electron microscopy(SEM)observation.The toughness mechanism of the modified EP was also discussed.Finally,the thermal stability of the modified EP was improved by the addition of GOS.Compared with neat EP,the initial thermal degradation temperature and glass transition temperature of GOS modified EP increased by 4.5℃and 10.3℃,respectively.

Effect of heating-rate on failure temperature of pre-loaded brass H62

The response and failure of brass H62 specimens subjected to different levels of pre-loaded stresses and heating rates were investigated using a Gleeble-1500 thermal-mechanical material testing system. The metallographs of the tested material were also observed and analyzed. It is found that the increase of either pre-loaded stress or heating-rate decreases the failure temperature. Metallographic analysis shows that high heating-rate may cause stronger local thermal inconsistency(LTI) and remarkably increase the microdefects in the material,which may markedly degrade the macroscopic mechanical properties of the material.

光伏电池正向电流注入下的电流集边效应仿真分析

针对光伏电池在正向电流注入条件下,电极表面电流分布及电池表面温度分布情况,采用COMSOL Multiphysics仿真软件对光伏电池进行建模仿真。建立三维光伏电池模型,通过数值模拟光伏电池在大电流正向注入情况下的载流子输运过程,求解载流子电流密度沿主栅方向分布。仿真结果表明:由于电池片内部载流子的横向输运过程,细栅边缘处横向电流密度达到峰值,且总电流密度向细栅、主栅方向集中;随着外加电压的增大,电池片表面的温度也不断升高,且表面温度最高点集中在次主栅根部,理论求解出最大允许正向电压阈值。