NiCoCrAlY/YSZ梯度涂层热力学性能的有限元模拟

王士峰; 夏明岗; 刘明; 王玉; 王斌; 白宇; 王海斗

doi:10.11868/j.issn.1005-5053.2022.000059

NiCoCrAlY/YSZ梯度涂层热力学性能的有限元模拟

doi: 10.11868/j.issn.1005-5053.2022.000059

王士峰¹,
夏明岗²,
刘明³,
王玉¹,
王斌²,
白宇^1, ,,
王海斗³

1.
西安交通大学金属材料强度国家重点实验室, 西安 710049
2.
西安交通大学物理学院物质非平衡合成与调控教育部重点实验室, 西安 710049
3.
陆军装甲兵学院装备再制造技术国防科技重点实验室, 北京 100072

基金项目: 国家自然科学基金重点项目（52130509）；国家自然科学基金面上项目（52075542）；国家自然科学基金青年项目（52005388）

详细信息

通讯作者:
白宇（1983—），男，博士，教授，主要从事新型陶瓷涂层、金属陶瓷复合涂层的研究，联系地址：陕西省西安市碑林区咸宁西路28号西安交通大学（710049），E-mail：byxjtu@mail.xjtu.edu.cn

中图分类号: TG148
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出版历程
- 收稿日期: 2022-04-18
- 修回日期: 2022-05-18
- 网络出版日期: 2022-10-11
- 刊出日期: 2023-02-01

Finite element simulation of thermodynamic properties of NiCoCrAlY/YSZ gradient coating

1.
State Key Laboratory for Mechanical Behavior of Materials, Xi’an Jiaotong University, Xi’an 710049, China
2.
School of Physics, MOE Key Laboratory for Non-equilibrium Synthesis and Modulation of Condensed Matter, Xi’an Jiaotong University, Xi’an 710049, China
3.
National Key Laboratory for Remanufacturing, Army Academy of Armored Forces, Beijing 100072, China

摘要

摘要: 采用代表体积单元法建立NiCoCrAlY/YSZ梯度热障涂层的有限元二维微观模型，计算不同相成分配比下梯度层的热物理性能参数，将参数结果推广到三维多层涂层实体模型，研究热循环过程中双层结构涂层和梯度结构涂层的热力学性能。结果表明：梯度层的弹性模量、泊松比、热膨胀系数、导热系数与各相成分比例近似呈线性关系，导热系数受各相分布形态的影响；当梯度层中NiCoCrAlY相成分比例在0.7以下时，导热系数较低，常温状态最高为2.91 W·m⁻¹·K⁻¹。相比于双层结构涂层，梯度结构涂层的YSZ成分比例降低20%，隔热温度降低14%，陶瓷面层在高温时产生的热失配径向拉应力降低47%，轴向拉应力降低32%，切应力降低37%，冷却后的残余应力降低50%，这归因于涂层结构的梯度化有效降低涂层与基体热膨胀系数不同而产生的热失配应力。根据涂层应力分布结果，涂层易在TC/BC界面的中心区域形成垂直裂纹，靠近外侧边缘区形成水平裂纹。
- 热障涂层 /
- 梯度结构 /
- 有限元 /
- 微观模型 /
- 热应力
Abstract: The two-dimensional finite element microscopic model of NiCoCrAlY/YSZ gradient thermal barrier coating was established by using the representative volume element method to calculate the thermophysical properties of the gradient layer under different composition ratios. The parameter results were extended to the three-dimensional multi-layer solid model to study the thermodynamic properties of the double-layer coating and gradient structured coating under thermal cycling condition. The results show that the elastic modulus, Poisson's ratio, coefficient of thermal expansion and thermal conductivity of the gradient layer are approximately linear with the component proportion of each phase, and the thermal conductivity is also affected by the distribution pattern of each phase. The thermal conductivity is low and the highest value is 2.91 W·m⁻¹·K⁻¹ when the proportion of NiCoCrAlY phase in the gradient layer is below 0.7 at room temperature. Compared with the double-layer coating, the proportion of YSZ in gradient coatings is reduced by 20%, the insulation temperature is reduced by 14%, the radial tensile stress, axial tensile stress, and shear stress of the ceramic surface layer at high temperature are reduced respectively by 47%, 32% and 37%, and the residual stress after cooling is reduced by 50%. The results are attributed that the gradient of the coating structure can effectively reduce the thermal mismatch stress caused by the difference in the thermal expansion coefficient between coating and substrate. According to the results of coating stress distribution, the coating is inclined to form vertical cracks in the centre region and horizontal cracks near the outer edge of the TC/BC interface.
- thermal barrier coating /
- gradient structure /
- finite element /
- microscopic model /
- thermal stress

HTML全文

图 1 梯度结构热障涂层　（a）显微结构形貌；（b）微观结构模型

Figure 1. Gradient structured thermal barrier coating　（a）microstructure morphology；（b）microstructural model

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图 2 梯度层的热物理性能参数分析模型的边界条件　（a）弹性模量及泊松比；（b）导热系数；（c）热膨胀系数

Figure 2. Boundary conditions of thermophysical properties analysis model of gradient layer 　（a）elasticity modulus and Poisson’s ratio；（b）thermal conductivity；（c）coefficient of thermal expansion

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图 3 涂层系统的实体结构有限元模型　（a）实体模型；（b）双层结构涂层；（c）三层梯度涂层；（d）五层梯度涂层

Figure 3. Solid structure finite element model of coating system　（a）solid model；（b）double-layer coating；（c）three-layer gradient coating；（d）five-layer gradient coating

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图 4 不同温度下梯度层的热物理性能参数随NiCoCrAlY相比例变化曲线　（a）弹性模量；（b）泊松比；（c）导热系数；（d）热膨胀系数；（e）热容；（f）密度

Figure 4. Variation curves of thermophysical properties of the gradient layer with different proportion of NiCoCrAlY phase at different temperatures 　（a）elasticity modulus；（b）Poisson's ratio；（c）thermal conductivity；（d）coefficient of thermal expansion；（e）thermal capacity；（f）density

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图 5 涂层热导率的有限元计算结果与实验测试结果

Figure 5. Finite element calculation results and experimental test results of the thermal conductivity of coating

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图 6 不同结构涂层的隔热模拟结果　（a）涂层轴向温度分布；（b）涂层隔热性能对比

Figure 6. Thermal insulation simulation results of coatings with different structures　（a）axial temperature distribution of coatings；（b）comparison of insulation properties of coatings

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图 7 不同结构涂层的合金底层产生的剪切应力　（a）高温状态；（b）室温状态

Figure 7. Shear stresses generated in alloy base layers with different structural coatings 　（a）high temperature condition；（b）room temperature condition

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图 8 不同结构涂层的陶瓷面层产生的最大轴向拉应力

Figure 8. Maximum axial tensile stresses generated in ceramic top layers with different structural coatings

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图 9 不同结构涂层的陶瓷面层产生的径向拉应力对比　（a）各涂层产生的最大径向拉应力；（b）双层、三层梯度、五层梯度涂层应力分布；（c）三层梯度涂层应力分布；（d）五层梯度涂层应力分布

Figure 9. Comparison of the maximum radial tensile stresses generated in ceramic top layers with different structural coatings 　（a）maximum radial tensile stress generated in each coating；（b）stress distributions in double-layer, three-layer gradient and five-layer gradient coatings；（c）stress distribution in three-layer gradient coating；（d）stress distribution in five-layer gradient coating

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表 1 材料热物理性能参数^[15-16]

Table 1. Thermophysical properties of materials^[15-16]

Material	Temperature/℃	E/GPa	ν	α/(10⁻⁶·K⁻¹)	κ/(W·m⁻¹·K⁻¹)	C/(J·kg⁻¹·K⁻¹)	ρ/(kg·m⁻³)
YSZ	20	105.4	0.25	7.9	1.032	500	4580
	200	—	0.25	8.77	1.032	—	4580
	400	—	0.25	9.46	0.911	576	4580
	600	—	0.25	10.34	0.788	—	4580
	800	—	0.25	10.71	0.661	637	4580
	1000	—	0.25	11.70	0.622	—	4580
	1100	—	0.25	12.20	0.622	—	4580
NiCoCrAlY	20	200	0.30	13.6	5.8	400	8100
	200	190	0.30	14.2	7.5	400	8100
	400	175	0.31	14.6	9.5	400	8100
	600	160	0.31	15.2	12.0	400	8100
	800	145	0.32	16.1	14.5	400	8100
	1000	120	0.33	17.2	16.2	400	8100
	1100	110	0.33	17.6	17.0	400	8100
Casting aluminum alloy	20	84	0.32	21.0	130	400	2680
Casting aluminum alloy	400	70	0.32	21.8	148	400	2680

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表 2 双层涂层和梯度涂层的层数和成分比例

Table 2. Number of layer and composition ratios of double-layer coating and gradient coating

Coating type	Model	Layer	Proportion of NiCoCrAlY in each layer
Double-layer coating	G0	—	—
Three-layer gradient coating	G3-1	3	0.2	0.5	0.8
	G3-2	3	0.3	0.5	0.7
	G3-3	3	0.4	0.5	0.6
Five-layer gradient coating	G5-1	5	0.2	0.3	0.5	0.7	0.8
	G5-2	5	0.2	0.4	0.5	0.6	0.8
	G5-3	5	0.3	0.4	0.5	0.6	0.7

下载: 导出CSV

表 3 网格无关性验证结果

Table 3. Grid independent validation results

Gradient structure	Model parameter
Gradient structure	Element size/μm	Element number	Maximum mises/MPa
SUB	100-1000	204000	308.35
SUB	50-1000	240000	308.38
BC and GC	25	80000	308.35
BC and GC	16	128000	308.37
TC	50	240000	316.61
TC	37.5	320000	320.71

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