Design and optimization of plasma sprayed thermal barrier coating using finite element analysis

Thermal barrier coatings are utilized in hot sections of gas turbines in order to isolate parts imposed to elevated working temperature and in consequent enhance efficiency. In the current research, ABAQUS commercial finite element package was used to analyze temperature distribution and imposed residual stress in thermal barrier coating with s inusoidal interfaces. Allphysical, thermal and mechanical properties need for simulation was introduced in temperature- dependency mode to the software. Results indicated that, significant thermal load, distortion and of course, induced stress were concentrated in the upper protective ceramic layer and functionally grading strategy cause to a 50% reduction in residual stress in the coating system. The sign of stress and also trends of stress variation in interface asperity posses a specific pattern both in heating and cooling to ambient temperature.