Measurement and Understanding the Residual Stress Distribution as a Function of Depth in Atmosphere Plasma Sprayed Thermal Barrier Coatings

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Abstract

Residual stresses are generally considered to be the driving forces for the failure of APS TBCs. In this thesis, the residual stress distribution as a function of depth in APS TBC has been measured by synchrotron XRD and explained by image based modelling based on the microstructure detailed studied by SEM and CT. The residual stress/ strain distribution as a function of depth was measured by synchrotron XRD in transmission and reflection geometry. The residual stress/ strain values were analysed using full pattern Rietveld refinement, the sin square psi method and XRD2 method. For the reflection geometry, a new method was developed to deconvolute the residual stress value in each depth from the measured averaged values. Two types of residual stress/strain distribution were observed. The first kind of residual stress was found to be compressive and followed a non-linear trend, which increased from the surface to the interface, decreased slightly and increased again to the interface. This trend showed a jump feature near the interface. The second kind of residual stress distribution possessed two jump features: one near the interface similar to the first kind and another jump feature near the sample surface. The residual stress in both beta and gama phase in the bond coat were also investigated which showed a tensile stress state. The stress trend predicted by our analytical model followed a linear relationship. Comparing this with the first kind of residual stress distribution, two main differences were shown. Firstly the jump feature near the interface and secondly the much larger overall stress gradient. The 3D and 2D microstructure of the sample with the first kind of residual stress distribution was observed by X-ray CT and SEM. The effect of pores, inter-splat cracks and the rumpling interface on the residual stress distribution was investigated by image based modelling. It was proved that the pores and the inter-splat cracks had no large influence on the stress distribution and the jump feature near the interface was a result of the rumpling interface. The much larger stress gradient observed in the measured residual stress distribution was an indication of the stress relaxation in the coating which was proved by a specially designed mechanical test. To explain the jump feature near the sample surface in the second kind of stress distribution. 3D microstructures of the measured samples were observed using X-ray CT. The effect of vertical and the side cracks on the stress distribution were investigated by image based modelling. It was found that the vertical crack had no large influence on the residual stress distribution and the jump feature in the stress trend near the surface could be attributed to the side crack. The effect of other kinds of cracks that were not directly observed in our samples, such as middle or through side cracks, were also investigated. These results were used to develop a semi-destructive method to determine the existence and distribution of cracks in APS TBC

Keyword(s)

Computed Tomography; Digital Image Correlation; Image Based Modelling; Residual Stress; Synchrotron XRD; Thermal Barrier Coating

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