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A Theoretical Model for Predicting Residual Stress Generation in Fabrication Process of Double-Ceramic-Layer Thermal Barrier Coating System

机译：双层陶瓷热障涂层系统制造过程中残余应力产生的理论模型

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Residual stress arisen in fabrication process of Double-Ceramic-Layer Thermal Barrier Coating System (DCL-TBCs) has a significant effect on its quality and reliability. In this work, based on the practical fabrication process of DCL-TBCs and the force and moment equilibrium, a theoretical model was proposed at first to predict residual stress generation in its fabrication process, in which the temperature dependent material properties of DCL-TBCs were incorporated. Then, a Finite Element method (FEM) has been carried out to verify our theoretical model. Afterwards, some important geometric parameters for DCL-TBCs, such as the thickness ratio of stabilized Zirconia (YSZ, ZrO2-8%Y2O3) layer to Lanthanum Zirconate (LZ, La2Zr2O7) layer, which is adjustable in a wide range in the fabrication process, have a remarkable effect on its performance, therefore, the effect of this thickness ratio on residual stress generation in the fabrication process of DCL-TBCs has been systematically studied. In addition, some thermal spray treatment, such as the pre-heating treatment, its effect on residual stress generation has also been studied in this work. It is found that, the final residual stress mainly comes from the cooling down process in the fabrication of DCL-TBCs. Increasing the pre-heating temperature can obviously decrease the magnitude of residual stresses in LZ layer, YSZ layer and substrate. With the increase of the thickness ratio of YSZ layer to LZ layer, magnitudes of residual stresses arisen in LZ layer and YSZ layer will increase while residual stress in substrate will decrease.
机译：双层陶瓷热障涂层系统（DCL-TBC）的制造过程中产生的残余应力对其质量和可靠性有重要影响。在这项工作中，基于DCL-TBCs的实际制造过程以及力和力矩的平衡，首先提出了一个理论模型来预测其制造过程中的残余应力产生，其中DCL-TBCs的温度依赖性材料特性为合并。然后，进行了有限元方法（FEM）来验证我们的理论模型。之后，DCL-TBC的一些重要几何参数，例如稳定的氧化锆（YSZ，ZrO2-8％Y2O3）层与锆酸镧（LZ，La2Zr2O7）层的厚度比，可以在制造过程中大范围调整，其厚度比对其性能有显着影响，因此，已经系统地研究了该厚度比对DCL-TBCs制造过程中残余应力产生的影响。另外，在这项工作中还研究了一些热喷涂处理，例如预热处理，它对残余应力产生的影响。发现最终残余应力主要来自DCL-TBC制造过程中的冷却过程。提高预热温度可以明显降低LZ层，YSZ层和基板中的残余应力大小。随着YSZ层与LZ层的厚度比的增加，LZ层和YSZ层中产生的残余应力的大小将增加，而基板中的残余应力将减小。

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