Ananalyticalmodelofrumplinginthermalbarriercoatings-.PDFVIP

ARTICLE IN PRESS Journal of the Mechanics and Physics of solids 53 (2005) 949–973 /locate/jmps An analytical model of rumplingin thermal barrier coatings D.S. Balint?, J.W. Hutchinson Division of Engineering and Applied Sciences, Harvard University, Cambridge, MA 02138, USA Received 6 May 2004; accepted 4 November 2004 Abstract Multilayer thermal barrier coatings (TBCs) deposited on superalloy turbine blades provide protection from combustion temperatures in excess of 1500 1C. One of the dominant failure modes comprises cracking from undulation growth, or rumpling, of the highly compressed oxide layer that grows between the ceramic top coat and the intermetallic bond coat. In this paper, a mechanistic model providingan analytical approximation of undulation growthis presented for realistic cyclic thermal histories. Thickening, lateral growth straining and high temperature yieldingof the oxide layer are taken into account. Undulation growthin TBC systems is highly nonlinear and characterized by more than 20 material and geometric parameters, highlighting the importance of a robust yet computationally ef?cient model. At temperatures above 600 1C, the bond coat creeps. Thermal expansion mismatch occurs between the superalloy substrate and the oxide layer and, in some systems, the bond coat. In addition, some bond coats, such as PtNiAl, exhibit a martensitic phase transformation accompanied by nearly a 1% linear expansion, giving rise to a large effective mismatch. These two mismatches promote undulation growth. Nonlinear interaction between the stress in the bond coat induced by the constrainingeffect of the thick substrate and normal tractions applied at the surface of the bond coat by the compressed, undulatingoxide layer produces