基于内聚力模型的热障涂层失效行为研究
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摘要
热障涂层以其优异的隔热、耐磨和耐蚀性而被广泛应用于航空涡轮发动机中,其能够提高发动机的热效率和延长涡轮叶片的使用寿命。热障涂层的失效往往是裂纹扩展导致,其主要失效形式为表面开裂和界面分层失效。针对热障涂层的裂纹扩展行为,最重要也最直接的研究方法就是对热障涂层的整个损伤失效过程进行数值模拟,以便深入了解涂层失效过程及失效机理。内聚力模型能够比较精确地描述界面开裂问题,在一定程度上可减轻甚至消除裂纹尖端的应力奇异性,可以模拟任意裂纹扩展,故而在裂纹扩展研究中得到了广泛应用。采用内聚力模型模拟热障涂层表面开裂和界面分层失效的过程中,通常把内聚力单元预埋在可能出现裂纹的实体单元之间,当材料发生破坏时,裂纹就会沿着内聚力单元排布的方向形成和扩展。然而造成热障涂层损伤失效的因素较多,失效机理复杂,以及内聚力模型本身的缺陷性,使得利用内聚力模型模拟热障涂层失效过程的研究还不够全面。目前已经通过内聚力模型实现了热障涂层的损伤失效过程模拟,包括表面开裂过程和界面分层失效过程。当前研究大多忽略了涂层内部的微细观缺陷而将热障涂层视为均质材料进行研究,并且内聚力模型本身还存在一些问题,如参数的确定等。随着热障涂层的发展以及对内聚力模型认识的不断加深,内聚力模型模拟热障涂层损伤失效过程也在不断发展与完善。在表面开裂模拟方面,通过在陶瓷涂层内垂直嵌入内聚力单元来模拟陶瓷层内表面裂纹的扩展行为。陶瓷涂层内裂纹扩展行为的模拟大多采用扩展有限元法,内聚力模型的应用相对较少,而内聚力模型可有效解决界面开裂问题,特别是粘结层/陶瓷界面开裂问题,故而被广泛应用于热障涂层界面失效问题的研究中。本文对内聚力模型进行了简要介绍,总结了内聚力模型在模拟热障涂层损伤失效过程方面的研究进展,指出了当前研究中存在的问题并对其下一步的发展进行了展望。
Thermal barrier coatings( TBCs) hold widespread applications in gas turbines and aero engines because of their excellent thermal insulation,wear and corrosion resistance,which can improve engine thermal efficiency and prolong the service life of turbine blades. Generally,the failure of thermal barrier coatings is caused by the crack propagation,and the major failure modes consist of surface cracking and interface delamination. Concerning the crack propagation behavior of coatings,the most important and direct research approaches is to numerically simulate the entire failure process of the thermal barrier coatings,so as to acquire deep understanding of the mechanism of coating failure.The cohesive zone model( CZM) is capable of describing the interface cracking problem accurately,reducing or even relieving the stress singularity at the crack tip,and simulating the propagation of any crack without defining the pre-crack. When CZM is employed to simulate the process of surface cracking and interfacial delamination of the thermal barrier coatings,the cohesive unit is usually embedded between solid elements where cracks may occur. Once the material is destroyed,the cracks will form and expand along the direction of the cohesive unit. Nevertheless,the damage failure of TBCs are affected by diverse factors accompanied by complex failure mechanism. The variety of failure modes and the insufficiency of the CZM itself make CZM fail to describe the whole picture in study of thermal barrier coatings failure.At present,the simulation of damage failure process of TBCs has been realized by CZM,including the surface cracking process and the interface layer failure process. However,the majority of current studies regard the TBCs as homogenous materials and neglect the micro-defects inside the coating. Moreover,there is still some problems in CZM itself,such as the determination of parameters. With the advance of the TBCs and CZM,and the deepening of understanding to CZM,the simulation of failure process of TBCs by the CZM has been developed and improved continuously. Regarding to the simulation of surface cracking,the CZM is embedded vertically in the ceramic coating to simulate the expansion behavior of the internal surface cracks in the ceramic layer. Concerning the simulation of the crack growth behavior inside the ceramic coatings,the extended finite element method is commonly adopted,while CZM is seldom used. The CZM can effectively solve the problem of interface cracking,especially the bonding layer/ceramic interface cracking problem,it is widely employed in the study of interface failure problem of TBCs.In this article,we give a brief introduction of the CZM,summarize the progress of CZM in simulating the failure behavior of the TBCs,and finally point out problems in the current research and the future development direction.
Thermal barrier coatings( TBCs) hold widespread applications in gas turbines and aero engines because of their excellent thermal insulation,wear and corrosion resistance,which can improve engine thermal efficiency and prolong the service life of turbine blades. Generally,the failure of thermal barrier coatings is caused by the crack propagation,and the major failure modes consist of surface cracking and interface delamination. Concerning the crack propagation behavior of coatings,the most important and direct research approaches is to numerically simulate the entire failure process of the thermal barrier coatings,so as to acquire deep understanding of the mechanism of coating failure.The cohesive zone model( CZM) is capable of describing the interface cracking problem accurately,reducing or even relieving the stress singularity at the crack tip,and simulating the propagation of any crack without defining the pre-crack. When CZM is employed to simulate the process of surface cracking and interfacial delamination of the thermal barrier coatings,the cohesive unit is usually embedded between solid elements where cracks may occur. Once the material is destroyed,the cracks will form and expand along the direction of the cohesive unit. Nevertheless,the damage failure of TBCs are affected by diverse factors accompanied by complex failure mechanism. The variety of failure modes and the insufficiency of the CZM itself make CZM fail to describe the whole picture in study of thermal barrier coatings failure.At present,the simulation of damage failure process of TBCs has been realized by CZM,including the surface cracking process and the interface layer failure process. However,the majority of current studies regard the TBCs as homogenous materials and neglect the micro-defects inside the coating. Moreover,there is still some problems in CZM itself,such as the determination of parameters. With the advance of the TBCs and CZM,and the deepening of understanding to CZM,the simulation of failure process of TBCs by the CZM has been developed and improved continuously. Regarding to the simulation of surface cracking,the CZM is embedded vertically in the ceramic coating to simulate the expansion behavior of the internal surface cracks in the ceramic layer. Concerning the simulation of the crack growth behavior inside the ceramic coatings,the extended finite element method is commonly adopted,while CZM is seldom used. The CZM can effectively solve the problem of interface cracking,especially the bonding layer/ceramic interface cracking problem,it is widely employed in the study of interface failure problem of TBCs.In this article,we give a brief introduction of the CZM,summarize the progress of CZM in simulating the failure behavior of the TBCs,and finally point out problems in the current research and the future development direction.
引文
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2 Marino K A,Hinnemann B,Carter E A.Proceedings of the National Academy of Sciences of the United States of America,2011,108(14),5480.
3 B?ker M,Seiler P.Journal of Thermal Spray Technology,2017,26(6),1146.
4 Yang L,Zhou Y C,Lu C.Acta Materialia,2011,59(17),6519.
5 Wang L,Ni J X,Shao F,et al.Journal of Thermal Spray Technology,2017,26(1-2),116.
6 Yang Li.Nondestructive evaluation of oxidation,damage and fracture of thermal barrier coatings.Ph.D.Thesis,Xiangtan University,China,2007(in Chinese).杨丽.热障涂层氧化、损伤与断裂的无损评价研究.博士学位论文,湘潭大学,2007.
7 Zhou Y C,Liu Q X,Yang L,et al.Acta Mechanica Solida Sinica,2010,31(5),504(in Chinese).周益春,刘奇星,杨丽,等.固体力学学报,2010,31(5),504.
8 Jin G H,Damage and failure analysis of heterogeneous materials based on cohesive zone model.Master's Thesis,Zhejiang University of Technology,China,2015(in Chinese).靳国辉.基于内聚力模型非均质材料损伤与失效的数值研究.硕士学位论文,浙江工业大学,2015.
9 Gu Z P,Study on delamination failure mechanism of composite laminates based on cohesive theory.Master's Thesis,Zhejiang University,China,2016(in Chinese).顾志平.基于内聚力理论的复合材料分层失效机理研究.硕士学位论文,浙江大学,2016.
10 Mcgarry J P,éamonn ó Máirtín,Parry G,et al.Journal of the Mechanics & Physics of Solids,2014,63(1),336.
11 éamonn ó Máirtín,Parry G,Beltz G E,et al.Journal of the Mechanics & Physics of Solids,2014,63(1),363.
12 Huang L G.The analysis of cohesive zone model and user-defined subroutine development in finite element method.Master's Thesis,Zhengzhou University,China,2010(in Chinese).黄刘刚.内聚力模型的分析及有限元子程序开发.硕士学位论文,郑州大学,2010.
13 Dugdale D S.Journal of the Mechanics & Physics of Solids,1960,8(2),100.
14 Barenblatt G I.Advances in Applied Mechanics,1962,7,55.
15 Li Zhuo,The application of CZM and XFEM methods on crack propagation simulation.Master's Thesis,Guangxi University,China,2013(in Chinese).李卓.内聚力和扩展有限元方法在裂纹扩展模拟中的应用研究.硕士学位论文,广西大学,2013.
16 Sun J Q,Ji D M,Tan J Z,et al.Journal of Shanghai University of Electric Power,2016,32(2),129(in Chinese).孙家啟,纪冬梅,唐家志,等.上海电力学院学报,2016,32(2),129.
17 Zhou M,Yao W B,Yang X S,et al.Surface & Coatings Technology,2014,240(7),40.
18 Yang L,Zhou Y C,Mao W G,et al.Applied Physics Letters,2008,93(23),299.
19 Bia?as M,Majerus P,Herzog R,et al.Materials Science & Engineering A,2005,412(1-2),241.
20 Yang X S.Finite element analysis of failure process of thermal barrier coatings by using cohesive element.Master's Thesis,Xiangtan University,China,2013(in Chinese).杨雪松.基于内聚力单元热障涂层体系失效过程有限元模拟分析.硕士学位论文,湘潭大学,2013.
21 Wang L,Li D C,Yang J S,et al.Journal of the European Ceramic Society,2016,36(6),1313.
22 Yang X S,Wan J,Dai C Y,et al.Surface & Coatings Technology,2013,223(52),87.
23 Fan X L,Xu R,Zhang W X,et al.Applied Surface Science,2012,258(24),9816.
24 Fan X,Zhang W,Wang T,et al.Applied Surface Science,2011,257(15),6718.
25 Wang L,Yang J S,Ni J X,et al.Surface & Coatings Technology,2016,285,98.
26 Fleck N A,Cocks A C F,Lampenscherf S.Journal of the European Ceramic Society,2014,34(11),2687.
27 Moridi A,Azadi M,Farrahi G H.Surface & Coatings Technology,2014,243(4),91.
28 Wang L,Zhao Y X,Zhong X H,et al.Journal of Thermal Spray Technology,2014,23(3),431.
29 Vermaak N,Michailidis G,Estevez R,et al.Structural & Multidisciplinary Optimization,2014,50(4),623.
30 Nordhorn C,Mücke R,VaBen R.Surface & Coatings Technology,2014,258,181.
31 Aleksanoglu H,Scholz A,Oechsner M,et al.International Journal of Fatigue,2013,53(7),40.
32 Wu D J,Mao W G,Zhou Y C,et al.Applied Surface Science,2011,257(14),6040.
33 Chen Z B,Wang Z G,Zhu S J.Surface & Coatings Technology,2011,205(15),3931.
34 Yao W B,Dai C Y,Mao W G,et al.Surface & Coatings Technology,2012,206(18),3803.
35 Qian L,Zhu S,Kagawa Y,et al.Surface & Coatings Technology,2003,173(2-3),178.
36 Zhu W,Yang L,Guo J W,et al.Applied Surface Science,2014,315(315),292.
37 Zhu W,Yang L,Guo J W,et al.In:National Physical and Mechanical Conference.Xiangtan,2014,pp.76.
38 Yang L,Zhong Z C,You J,et al.Surface & Coatings Technology,2013,232(10),710.
39 Yang L,Zhong Z C,Zhou Y C,et al.Journal of Mechanics,2016,32(2),1.
40 Guo S,Kagawa Y.Scripta Materialia,2004,50(11),1401.
41 Xia S Q.The research of the crack propagation in thermal spray remanufacturing product.Master's Thesis,Beihang University,China,2016(in Chinese).夏世琦.热喷涂再制造件的裂纹扩展行为研究.硕士学位论文,北京航空航天大学,2016.
42 Leo C V D,Luk-Cyr J,Liu H,et al.Acta Materialia,2014,71(1),306.
43 Hille T S,Suiker A S J,Turteltaub S.Engineering Fracture Mechanics,2009,76(6),813.
44 Yao W B,Dai C Y,Mao W G,et al.Surface & Coatings Technology,2012,206(18),3803.
45 Qian L,Zhu S,Kagawa Y,et al.Surface & Coatings Technology,2003,173(2-3),178.
46 Zhu W,Yang L,Guo J W,et al.Applied Surface Science,2014,315(315),292.
47 Chen X,Hutchinson J W,He M Y,et al.Acta Materialia,2003,51(7),2017.
48 Busso E P,Wright L,Evans H E,et al.Acta Materialia,2007,55(5),1491.
49 Wang L,Fan Q,Liu Y,et al.Materials & Design,2015,86,89.
50 Bialas M.Surface & Coatings Technology,2008,202(24),6002.