Quantitative Characterization of Interlaminar Mechanical Properties of Heterogeneous Thermal Barrier Coating Structures on Ni-Based Superalloys AITranslate
Abstract AITranslate
Thermal barrier coatings （TBCs） are advanced materials systems extensively applied in extreme environments, such as aeroengine hot-section components and gas turbines, due to their exceptional thermal insulation properties. These coatings typically consist of a ceramic top coat （TC） for thermal protection, a metallic bond coat （BC） to enhance adhesion and provide oxidation resistance, and nickel-based superalloy substrate. Despite their widespread use, the failure modes of TBCs under thermal cycling and mechanical stresses, mainlydelamination and spallation, are closely tied to the interfacial mechanical properties between eachlayers. Consequently, comprehensive and quantitative characterization of the interlaminar mechanical properties of nickel-based superalloy heterostructures with TBCs from room temperature to 900 ℃ is essential for offering valuable insights into the strength degradation patterns of these interfaces under realistic service conditions. To investigate the bond strength and interlaminar shear strength of TC/BC/superalloy substrate interfaces in TBCs, quasi-static simple tensile tests were systematically conducted over the temperature range from room temperature to 900 ℃. A controlled tensile load was applied to the coated specimens until failure occurred, allowing for the determination of the bond strength at the interfaces. The testing machine was equipped with a video extensometer, enabling non-contact real-time acquisition of displacement. The test specimens, prepared to ensure uniform coating thickness and adherence to standard specifications, were subjected to controlled tensile loading while being monitored for deformation and failure. A high-precision 4k industrial camera was positioned to capture detailed images of transverse crack propagation as well as the morphology of the fracture surfaces upon failureafter the experiments. This observational data provided valuable insights into the failure mechanisms and the nature of interfacial debonding. Additionally, to quantitatively assess the bond strength and interlaminar shear strength, the shear-lag theoretical model was employed. This model facilitated the development of an analytical method for interfacial stress transfermechanisms between the different layers of TBCs, allowing for the calculation of key parameters such as normal and shear stress distributions. Finite element analysis （FEA） incorporated with linear elastic constitutive theory was adopted to accurately represent the material behavior under tensile loading was also utilized to simulate the stress distribution within the coating and at the interfaces, providing additional validation and insights into the theoretical model. The results of the experimental studies revealed significant temperature-dependent variations in the interfacial mechanics of the multilayer hetero-structures of nickel-based superalloy with TBCs. The shear-lag theory analysis further quantified the bond strength and interlaminar shear strength of the top coat/bond coat/superalloy substrate interfaces in TBCs, confirming the theoretical predictions and providing a deeper and more nuanced understanding of the stress transfer mechanisms between the different layers. For BC/substrate interface, it was observed that the bond strength of the bond coat/substrate interface decreases markedly with increasing temperature. At 800 ℃, for instance, the bond strength exhibited a reduction of approximately 31.4% compared to its value at room temperature. This trend was attributed to the weakening of interatomic bonds and the potential for interfacial oxidation at elevated temperatures, which can weaken the interfacial adhesion. Similarly, TC/substrate interface demonstrated a comparable temperature sensitivity, with a notable reduction in interlaminar shear strength observed as the temperature rose. Particularly within 300~400 ℃, TC/substrate interface experienced a sharp decline in strength, with a 20% decrease recorded over this temperature interval. This behavior can be related to the thermal expansion mismatch between the top coat and the substrate. The high-resolution imaging provided by the industrial camera offered detailed insights into the crack propagation paths and fracture characteristics and donated a clear understanding of the failure mechanisms in TBCs. Cracks were observed to initiate at the interfaces and propagate transversely, weakening the structural integrity of the coatings and leading to eventual delamination and spallation of the coatings. Statistical methods were used to measure the average spacing of multiple cracks, and then the interfacial mechanical properties were quantitatively determined based on the shear-lag theory. The high-temperature experimental investigation of interface mechanical properties in multilayer hetero-structure TBCs, observed temperature-dependent variations in bond strength underscored the importance of considering thermal effects in the design and application of TBCs. The research contributes to the broader field of materials science by providing a deeper understanding of the failure mechanisms in TBCs and offering practical recommendations for improving their performance and reliability in extreme thermal environments. As aero-engine and gas turbine technologies continue to evolve towards higher operating temperatures and efficiencies, the knowledge gained from this study will be instrumental in advancing the development of next-generation thermal barrier coatings.
KeyWords AITranslate
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Basic Information:
DOI：10.13373/j.cnki.cjrm.XY25090005
Chinese Library Classification Number:TG174.4
Citation Information:
Thermal barrier coatings （TBCs） are advanced materials systems extensively applied in extreme environments, such as aeroengine hot-section components and gas turbines, due to their exceptional thermal insulation properties. These coatings typically consist of a ceramic top coat （TC） for thermal protection, a metallic bond coat （BC） to enhance adhesion and provide oxidation resistance, and nickel-based superalloy substrate. Despite their widespread use, the failure modes of TBCs under thermal cycling and mechanical stresses, mainlydelamination and spallation, are closely tied to the interfacial mechanical properties between eachlayers. Consequently, comprehensive and quantitative characterization of the interlaminar mechanical properties of nickel-based superalloy heterostructures with TBCs from room temperature to 900 ℃ is essential for offering valuable insights into the strength degradation patterns of these interfaces under realistic service conditions. To investigate the bond strength and interlaminar shear strength of TC/BC/superalloy substrate interfaces in TBCs, quasi-static simple tensile tests were systematically conducted over the temperature range from room temperature to 900 ℃. A controlled tensile load was applied to the coated specimens until failure occurred, allowing for the determination of the bond strength at the interfaces. The testing machine was equipped with a video extensometer, enabling non-contact real-time acquisition of displacement. The test specimens, prepared to ensure uniform coating thickness and adherence to standard specifications, were subjected to controlled tensile loading while being monitored for deformation and failure. A high-precision 4k industrial camera was positioned to capture detailed images of transverse crack propagation as well as the morphology of the fracture surfaces upon failureafter the experiments. This observational data provided valuable insights into the failure mechanisms and the nature of interfacial debonding. Additionally, to quantitatively assess the bond strength and interlaminar shear strength, the shear-lag theoretical model was employed. This model facilitated the development of an analytical method for interfacial stress transfermechanisms between the different layers of TBCs, allowing for the calculation of key parameters such as normal and shear stress distributions. Finite element analysis （FEA） incorporated with linear elastic constitutive theory was adopted to accurately represent the material behavior under tensile loading was also utilized to simulate the stress distribution within the coating and at the interfaces, providing additional validation and insights into the theoretical model. The results of the experimental studies revealed significant temperature-dependent variations in the interfacial mechanics of the multilayer hetero-structures of nickel-based superalloy with TBCs. The shear-lag theory analysis further quantified the bond strength and interlaminar shear strength of the top coat/bond coat/superalloy substrate interfaces in TBCs, confirming the theoretical predictions and providing a deeper and more nuanced understanding of the stress transfer mechanisms between the different layers. For BC/substrate interface, it was observed that the bond strength of the bond coat/substrate interface decreases markedly with increasing temperature. At 800 ℃, for instance, the bond strength exhibited a reduction of approximately 31.4% compared to its value at room temperature. This trend was attributed to the weakening of interatomic bonds and the potential for interfacial oxidation at elevated temperatures, which can weaken the interfacial adhesion. Similarly, TC/substrate interface demonstrated a comparable temperature sensitivity, with a notable reduction in interlaminar shear strength observed as the temperature rose. Particularly within 300~400 ℃, TC/substrate interface experienced a sharp decline in strength, with a 20% decrease recorded over this temperature interval. This behavior can be related to the thermal expansion mismatch between the top coat and the substrate. The high-resolution imaging provided by the industrial camera offered detailed insights into the crack propagation paths and fracture characteristics and donated a clear understanding of the failure mechanisms in TBCs. Cracks were observed to initiate at the interfaces and propagate transversely, weakening the structural integrity of the coatings and leading to eventual delamination and spallation of the coatings. Statistical methods were used to measure the average spacing of multiple cracks, and then the interfacial mechanical properties were quantitatively determined based on the shear-lag theory. The high-temperature experimental investigation of interface mechanical properties in multilayer hetero-structure TBCs, observed temperature-dependent variations in bond strength underscored the importance of considering thermal effects in the design and application of TBCs. The research contributes to the broader field of materials science by providing a deeper understanding of the failure mechanisms in TBCs and offering practical recommendations for improving their performance and reliability in extreme thermal environments. As aero-engine and gas turbine technologies continue to evolve towards higher operating temperatures and efficiencies, the knowledge gained from this study will be instrumental in advancing the development of next-generation thermal barrier coatings.
quote
| GB/T 7714-2015 | [1] Weixing Gong, Hanlin Wu, Yannan Gao, et al. Quantitative Characterization of Interlaminar Mechanical Properties of Heterogeneous Thermal Barrier Coating Structures on Ni-Based Superalloys[J]. Chinese Journal of Rare Metals, 2026, 50(8): 1278-1286. DOI:10.13373/j.cnki.cjrm.XY25090005. |
| MLA | [1] Weixing Gong, et al., "Quantitative Characterization of Interlaminar Mechanical Properties of Heterogeneous Thermal Barrier Coating Structures on Ni-Based Superalloys." Chinese Journal of Rare Metals, vol. 50, no. 8, 2026, pp. 1278-1286, https://doi.org/10.13373/j.cnki.cjrm.XY25090005. |
| APA | [1] Weixing Gong, Hanlin Wu, Yannan Gao, Baiming Xu, Duoqi Shi, & Hongyu Qi. (2026). Quantitative Characterization of Interlaminar Mechanical Properties of Heterogeneous Thermal Barrier Coating Structures on Ni-Based Superalloys. Chinese Journal of Rare Metals, 50(8), 1278-1286. https://doi.org/10.13373/j.cnki.cjrm.XY25090005 |
| IEEE | [1] Weixing Gong, Hanlin Wu, Yannan Gao, Baiming Xu, Duoqi Shi, and Hongyu Qi, "Quantitative Characterization of Interlaminar Mechanical Properties of Heterogeneous Thermal Barrier Coating Structures on Ni-Based Superalloys," Chinese Journal of Rare Metals, vol. 50, no. 8, pp. 1278-1286, 2026, doi: 10.13373/j.cnki.cjrm.XY25090005. keywords: {thermal barrier coatings;hetero-structures;simple tension;shear-lag theory;bond strength} |