Finite Element Simulation and Analysis of Deposition Process and Thermal Loading on Thermal Barrier Coatings

The need for a high-temperature operation to increase efficiency has led to the use of protective coatings called Thermal Barrier Coatings (TBCs) to protect turbine equipment against destructive conditions and relatively high thermal loads. However, the coatings themselves are also gradually affected by these destructive conditions. In the present study, based on the microstructural characteristics of thermal barrier coatings, first, the modeling of the deposition process and the fabrication of these coatings was done using the finite element method. In this modeling, the deposition process of TBCs for studying the thermal and mechanical behavior of these coatings simulated. Then the temperature field and the residual stresses obtained during and after the deposition process and cooling to ambient temperature has been studied. Subsequently, by applying thermal loading and simulating the actual working conditions of the turbine, the thermal and mechanical behavior of TBCs was evaluated in working conditions and the distribution of the temperature and stress field in the system was calculated. The results show that the maximum residual stress after cooling is at the interface between the substrate and the bond coat. The obtained results and the accuracy of the proposed model validated by experimental reports.