| XIE Lingling,FANG Tianyu,NIU Yaran,HONG Du,WANG Ziyu,ZHU Shichao,ZHENG Xuebin.Finite Element Simulation of Thermal Stress Evolution during the Deposition of a New Thermal Barrier Coating Prepared by Plasma Spraying on the Surface of TiAl Alloy[J],54(11):231-242 |
| Finite Element Simulation of Thermal Stress Evolution during the Deposition of a New Thermal Barrier Coating Prepared by Plasma Spraying on the Surface of TiAl Alloy |
| Received:October 13, 2024 Revised:January 23, 2025 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2025.11.020 |
| KeyWord:three-dimensional thermodynamic coupling simulation plasma spraying path-by-path and layer-by-layer thermal barrier coating thermal stress |
| Author | Institution |
| XIE Lingling |
School of Metallurgical Engineering, Anhui University of Technology, Anhui Maanshan , China |
| FANG Tianyu |
School of Metallurgical Engineering, Anhui University of Technology, Anhui Maanshan , China |
| NIU Yaran |
Key Laboratory of Inorganic Coating Materials, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai , China |
| HONG Du |
Key Laboratory of Inorganic Coating Materials, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai , China |
| WANG Ziyu |
School of Mechanical Engineering, Anhui University of Technology, Anhui Maanshan , China |
| ZHU Shichao |
College of Aeronautics and Mechanical Engineering, Changzhou Institute of Technology, Jiangsu Changzhou , China |
| ZHENG Xuebin |
Key Laboratory of Inorganic Coating Materials, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai , China |
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| Abstract: |
| TiAl alloy is considered as a potential alternative high temperature structural material in the aerospace field due to its low density, high specific strength, modulus and excellent high temperature durability and creep resistance. However, when TiAl alloy is in service above 850 ℃, its surface will produce loose structure oxidation products with no protective effect, and the oxidation resistance decreases sharply at high temperature. Therefore, the development of new Thermal Barrier Coatings (TBCs) has become the key to the application of TiAl alloy in the hot end parts of aeroengines. TBCs should be as close as possible to the properties of the substrate material, so as to ensure the collaborative deformation ability of TBCs and the substrate, and it is not easy to cause material cracking due to large deformation differences. TiAlCrY and TiAl alloy have similar composition, small difference in thermal expansion coefficient, good compatibility, and good high-temperature oxidation resistance, so it can not only reduce the mismatch of thermal physical parameters between the coating and TiAl alloy substrate, but also avoid the effect of element diffusion and can be used as a promising transition layer material for TiAl alloy. Therefore, atmospheric plasma spraying technology is used to prepare a thermal barrier coating system on the surface of TiAl alloy, with TiAlCrY as the transition layer and Yttrium oxide partially stabilized zirconia (7%-8%) Y2O3-ZrO2 (7-8YSZ) and other ceramic materials with low thermal conductivity as the spraying layer, which can improve the high temperature resistance and oxidation resistance of the alloy. The residual stress of the multilayer coating system is affected by the initial stress state of the substrate during preparation and the stress state after spraying and cooling, which is the key to obtain high performance and long life TBCs. Therefore, the deposition process of TiAlCrY/YSZ thermal barrier coating by plasma spraying on the surface of TiAl alloy is simulated through spraying by the way of the path-by-path and layer-by-layer based on finite element simulation with three-dimensional thermodynamic coupling. Most areas of the melted layer have compressive stress in x and y directions, but there is a small tensile stress at the beginning of the melted layer and a high compressive stress at the end of the melted layer in the process of spraying the TiAlCrY transition layer and YSZ thermal barrier coating, and when the z-direction stress is involved, the surface of the melted layer alternates between tensile stress and compressive stress, but there is a high tensile stress at the end of the melted layer. Due to the obvious difference in material properties, there is a sudden stress phenomenon at the interface of each layer of materials, especially the peak tensile and compressive stress at the interface of the transition layer and the spray layer. During the spraying process, due to the mutual thermal effect between layers and channels, there are multiple thermal stress cycles in the deposition process. In particular, the peak tensile and compressive stresses in the deposition process are significantly higher than the residual stress at cooling to room temperature. Therefore, the study results reveal the distribution and evolution of thermal stress during the deposition of the plasma sprayed thermal barrier coating on the surface of TiAl alloy, and reduce the possibility of coating cracking failure due to excessive residual stress, which provides guidance for the preparation of the new TiAlCrY/YSZ TBCs with accurately controllable stress state. |
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