Quantitative assessment of the surface crack density in thermal barrier coatings

In this paper, a modified shear-lag model is developed to calculate the surface crack density in thermal barrier coatings（TBCs）. The mechanical properties of TBCs are also measured to quantitatively assess their surface crack density. Acoustic emission（AE） and digital image correlation methods are applied to monitor the surface cracking in TBCs under tensile loading. The results show that the calculated surface crack density from the modified model is in agreement with that obtained from experiments. The surface cracking process of TBCs can be discriminated by their AE characteristics and strain evolution. Based on the correlation of energy released from cracking and its corresponding AE signals, a linear relationship is built up between the surface crack density and AE parameters, with the slope being dependent on the mechanical properties of TBCs.     

基于圆筒模型的热障涂层安定分析

热载荷作用下,由于热障涂层(thermal barrier coatings, TBCs) 各层材料的热不匹配以及材料参数的温度相关等因素,会使热障涂层界面区域存在复杂的应力应变场,影响系统安定性,并导致涂层开裂和剥落. 将热障涂层外凸和内凹微观界面结构简化为多层圆筒模型,借助经典机动安定定理,利用特雷斯卡(Tresca) 屈服准则和增量破坏准则处理对时间的积分问题,避免了常规安定性分析的数学规划问题,建立了热障涂层安定极限分析方法,将材料屈服强度随温度变化关系简化为双线性关系,利用补偿变换的方法简化求解过程,对典型热障涂层安定性进行了研究. 结果表明,利用基于圆筒的安定极限分析方法,能够方便求解安定极限,便于工程应用;热障涂层安定极限值明显高于弹性设计值,且界面外凸区域安定极限高于内凹区域极限值,结构首先在内凹处失效;圆筒模型基体曲率和涂层厚度越大,结构安定极限越高,分析结果与试验结果一致;所建立的热障涂层安定分析方法,对进一步研究考虑蠕变因素影响的热障涂层安定性具有重要意义.      

Parametric studies of failure mechanisms in elastic EB-PVD thermal barrier coatings using FEM

Catastrophic failure of thermal barrier coatings (TBCs), usually occurs due to large scale buckling and spallation, primarily originating at the bond coat and TGO interface. Spallation in TBCs is preceded by a competition between buckling and interface delamination that is stimulated by the waviness of the interface. In the presence of thermal loading, the waviness is responsible for growth of interfacial delamination. In this paper, a finite element model of the two and three layer TBC’s is developed in the commercial code ANSYS to investigate the buckle and interface delamination mechanisms and develop a simplified parametric understanding of these mechanisms. The models for simulation are validated with analytical and experimental results. Parametric relations, in terms of geometric and material parameters representing constituents of the TBC, are developed in this paper for critical stresses and energies causing buckling and debonding initiated instabilities. Through these relations, critical parameters that control failure mechanics are identified for a fail-safe design space.     

离散元法在求解三维冲击动力学问题中的应用

提出了三维连结型离散模型,建立了可实现连结型模型(用于连续介质)-接触型模型(用于非连续介质)转化的三维离散元计算程序,用来模拟连续介质转变为非连续介质的力学过程．利用该计算程序对冲击载荷下混凝土块体内(连续体情况下)的应力波传播过程进行了数值模拟．将计算结果的数值与LS-DYNA程序计算的结果进行比较,验证了该计算程序的计算精度．在此基础上,模拟了混凝土块体的动态破坏(连续介质向非连续介质转化)过程．其计算结果可用动画显示,得到的破坏形式与由实验得到的破坏形式相近．两个算例说明该离散元模型及其计算程序是模拟计算伴随有连续介质向非连续介质转变的动态破坏问题的有力工具．     

Analysis of the spallation mechanism suppression in plasma-sprayed TBCs through the use of heterogeneous bond coat architectures

This paper critically examines the use of heterogeneous bond coats to increase the durability of plasma-sprayed thermal barrier coatings under spatially-uniform cyclic thermal loading. A major failure mechanism in these types of coatings involves spallation of the top coat caused by the top/bond coat thermal expansion mismatch concomitant with deposition-induced top/bond coat interfacial roughness, oxide film growth and creep-induced normal stress reversal at the rough interface’s peaks. The reduction of the top/bond coat thermal expansion mismatch aimed at increasing coating durability can be achieved by embedding alumina particles in the bond coat. Herein, we analyze the evolution of local stress and inelastic strain fields in the vicinity of the rough top/bond coat interface during thermal cycling, and how these fields are influenced by the presence of spatially uniform and non-uniform (graded) distributions of alumina particles in the metallic bond coat. The analysis is conducted using the higher-order theory for functionally graded materials which accounts for the high-temperature creep/relaxation effects within the individual TBC constituents. In the presence of two-phase bond coat microstructures, both the actual and homogenized bond coat properties are employed in the analysis in order to highlight the limitations of the prevalent homogenization-based approach applied to graded materials. The results reveal that the use of heterogeneous, two-phase bond coats, with spatially uniform or graded microstructures, while slightly suppressing the normal stress component evolution in the interfacial peak region, increases the magnitude of the shear stress component as well as the inelastic strain evolution in this region, thereby potentially promoting delamination initiation. The analysis based on homogenized bond coat microstructure produces misleading results relative to how the bond coat heterogeneity affects the magnitude of the normal and shear stress, and inelastic strain, components.     

THE APPLICATION OF DISCRETE ELEMENT METHOD IN SOLVING THREE-DIMENTIONAL IMPACT DYNAMICS PROBLEMS

A three-dimensional discrete element model of the connective type is presented. Moreover, a three- dimensional numerical analysis code, which can carry out the transitional process from connective model (for continuum) to contact model (for non-continuum), is developed for simulating the mechanical process from continuum to non-continuum. The wave propagation process in a concrete block (as continuum) made of cement grout under impact loading is numerically simulated with this code. By comparing its numerical results with those by LS-DYNA, the calculation accuracy of the model and algorithm is proved. Furthermore, the failure process of the concrete block under quasi-static loading is demonstrated, showing the basic dynamic transitional process from continuum to non-continuum. The results of calculation can be displayed by animation. The damage modes are similar to the experimental results. The two numerical examples above prove that our model and its code are powerful and efficient in simulating the dynamic failure problems accompanying the transition from continuum to non-continuum. It also shows that the discrete element method (DEM) will have broad prospects for development and application.     

混凝土动态破坏过程超声波测试研究

混凝土在荷载作用下会产生损伤或破坏,用超声波的方法可测量损伤或破坏的程度。但在荷载作用下混凝土的破坏是一个动态过程,由于测试面发生变形,使常规超声波测试无法完成。本文研制了一个混凝土材料破坏过程超声波测试辅助装置,结合原有的非金属材料超声波检测仪,使测试混凝土材料动态破坏过程成为可能。同时通过辅助装置还可消除试件在破坏过程中由于变形带来的测试误差,可方便、快捷、准确地测试混凝土在荷载作用下的动态破坏过程。采用常规混凝土和冻融混凝土为试件,在材料万能试验机上进行了破坏实验,得到了不同荷载作用下超声波的波速。实验结果表明,混凝土的超声波波速随混凝土的破坏程度不断增大而减小,由此表示可采用超声波测试的方法确定混凝土的动态破坏过程。     

Intersonic crack propagation in homogeneous media under shear-dominated loading: theoretical analysis

The mechanics of cohesive failure under mixed-mode loading is investigated for the case of a steadily propagating subsonic and intersonic dynamic crack subjected to a follower tensile and shear distributed load. The cohesive failure model chosen in this study is rate independent but accounts for the coupling between normal and tangential damage. Special emphasis is placed here on mixed-mode cases with predominantly shear loading. The analysis shows that the size of the mixed-mode cohesive zone is smaller than that obtained in the pure shear case. The relative extent of the shear and tensile cohesive damage zones depends on the crack speed and the mode mixity. In the intersonic regime, the failure process takes place exclusively in shear, even under remote mixed-mode loading conditions.     

考虑面内破坏过程的含分层损伤复合材料加筋层合板的动力响应

基于复合材料层合板一阶剪切理论，推导了复合材料层合板单元的刚度阵和质量阵列式；同时采用了Adams应交能法与Rayleigh阻尼模型相结合的方法，构造了相应的阻尼阵列式；为了防止在低阶模态中分层处出现的上、下子板不合理的嵌入现象，建立了含分层损伤复合材料加筋层合板动力分析的分层分析模型和虚拟界面联接模型。在上述模型和理论基础上，采用了Tsai提出的刚度退化准则和动力响应分析的精细积分法，对含分层损伤复合材料加筋层合板结构进行了动力响应和破坏分析。通过算例，分别讨论了外载频率、分层位置，以及破坏过程的刚度退化对含损伤复合材料加筋层合板动力响应特征的影响，得到了一些具有理论和工程价值的结论。     

Investigation of thermo-elasto-plastic behavior of thick-walled spherical vessels with inner functionally graded coatings

Having high corrosion and thermal resistance characteristics, Functionally Graded Materials have been found wide range of applications in engineering fields. The analytical elasto-plastic solution for spherical vessels composed of outer homogenous part and inner FG coating under combined pressure and thermal loading is presented in this paper. Furthermore, the loading conditions resulted into onset of yielding from inner radius and fully plastic vessel are obtained. Material constituents in both homogenous and FG parts are assumed to be aluminum and SiC as metal matrix and ceramic particles, respectively. Although the amount of SiC particles in the homogenous part of vessel is assumed to be constant, it is varying in the radial direction of FG part based on the power law function. The results concerning two types of vessels with harder and softer FG coatings are also compared with those from homogenous vessel. Moreover, two dimensional finite element model was applied to simulate the process while the results were considered to verify the accuracy of the analytical solution. Generally, the results demonstrate that coating and grading behavior can really affect the stress distribution and yield pattern in the homogenous vessel with an inner FG coating.     

延性介质动态损伤模型

本文借鉴Johnson的基本方法,采用高应变率下的应力应变关系,以一个球形实体中含有球形空穴为基本力学单元,通过分析基元的受力状况,采用奇异摄动方法,推导出了空穴膨胀比的演化方程。方程中考虑了材料的硬化和应变率效应,同时又计及了惯性效应,在考虑空穴成校对损伤的影响时,采用了Chu和Needleman的结果,利用本文提出的模型对两个一维高速碰撞实验进行了数值模拟,计算结果与实验吻合较好。     

Residual Stress Analysis on Thick Film Systems by the Incremental Hole-Drilling Method – Simulation and Experimental Results

The residual stress state in thick film systems, as for example thermal spray coatings, is crucial for many of the component’s properties and for the evaluation of the integrity of the coating under thermal and/or mechanical loading. Therefore it is necessary to be able to determine the local residual stress distribution in the coating, at the interface and in the substrate. The incremental hole-drilling method is a widely used method for measuring residual stress depth profiles, which was already applied for thermally sprayed coatings. But so far no reliable hole-drilling evaluation method exists for layered materials having a stress gradient in depth. The objective was to investigate, how far existing evaluation methods of the incremental hole-drilling method that are only valid for residual stress analysis of homogenous material states can be applied to thick film systems with coating thicknesses between 50 μm and 1000 μm and to point out the application limits for these already existing methods. A systematic Finite Element (FE) study was carried out for coating systems with an axisymmetric residual stress state σ₁?=?σ₂. It is shown that conventional evaluation methods developed for homogeneous, non-layered material states can be successfully applied for a stress evaluation in the substrate and the coating for small and for sufficiently large coating thicknesses, respectively, regardless of the type of evaluation algorithm used i.e. the differential or the integral method. The same accounts for material combinations that have a Young’s modulus ratio close to one, between 0.8 and 1.2. The studies indicated that outside the given ranges case specific calibration must be applied to calculate reliable results. Further, calibration data were determined case specifically for a selected model coating system. The accuracy of a residual stress determination using these case specific calibration data was examined and the sensitivity of the evaluation with respect to an accurate knowledge of the boundary conditions of the coating system i.e. the coating thickness and the Young modulus was studied systematically. Finally, the calibration data were applied on a thermally sprayed aluminium coating on a steel substrate analysis and the results for using the incremental hole drilling method were compared to results from X-ray stress analysis.     

泡沫子弹冲击固支单梁的耦合分析模型

使用泡沫金属子弹进行冲击可以模拟爆炸载荷的作用,这一加载技术已被应用于防护结构的抗冲击性能测试中,然而泡沫子弹作用于被测试结构上的真实载荷以及二者间的相互作用过程尚不明晰.本文以泡沫子弹冲击固支梁的情形为例,开展了对该冲击过程的理论分析和数值模拟研究.基于泡沫材料的冲击波模型与固支单梁的结构冲击动力学响应模型,构建了描述泡沫子弹冲击固支梁过程的耦合分析模型.给出了不同响应阶段下子弹和单梁的动力学控制方程,并采用Runge-Kutta方法得到了方程的数值解.基于三维Voronoi技术,建立了泡沫子弹冲击固支单梁的有限元模型并进行了数值模拟.通过与有限元模拟结果的对比发现,相较于经典的脉冲加载模型,耦合分析模型能更好地预测泡沫子弹和单梁的速度变化规律,也能准确地预测子弹对单梁的真实冲击压强.当泡沫子弹的初始动量相同时,由于子弹自身的压溃行为,子弹的初始冲击速度、密度和长度的改变都会对冲击过程产生影响.最后,通过耦合分析模型分别分析了泡沫子弹的密度、长度、初速度对冲击压强的峰值、衰减速度和持续时间的影响,并针对具有不同特征的目标模拟载荷给出了泡沫子弹的筛选策略.所构建的耦合分析模型为研究泡沫...     

Creep-fatigue crack growth behavior of 304 stainless steel at 650°C

This study considers life prediction analysis of high temperature structures. In the case of failure under high temperature cyclic loading, material is damaged by cavity growth and crack propagates along the cavitated grain boundaries with higher growth rate. With this cavity damaging effects, a crack growth model has been developed. Using this model, computer simulation of life prediction has been performed for 304 stainless steel under various loading shapes at high temperatures.     

Acoustic emission assessment of interface cracking in thermal barrier coatings

In this paper, acoustic emission (AE) and digital image correlation methods were applied to monitor interface cracking in thermal barrier coatings under compression. The interface failure process can be identified via its AE features, including buckling, delamination incubation and spallation. According to the Fourier transformation of AE signals, there are four different failure modes: surface vertical cracks, opening and sliding interface cracks, and substrate deformation. The characteristic frequency of AE signals from surface vertical cracks is 0.21 MHz, whilst that of the two types of interface cracks are 0.43 and 0.29 MHz, respectively. The energy released of the two types of interface cracks are 0.43 and 0.29 MHz, respectively. Based on the energy released from cracking and the AE signals, a relationship is established between the interface crack length and AE parameters, which is in good agreement with experimental results.     

An application of a damage constitutive model to concrete at high temperature and prediction of spalling

A characteristic feature of concrete under uniaxial compression is the development of cracks parallel to the loading direction. A damage constitutive model proposed by Ortiz [Ortiz, M., 1985. A constitutive theory for the inelastic behaviour of concrete. Mech. Mater. 4, 67–93] can predict the transverse tensile stress responsible for these cracks by considering the interaction between the aggregate and the mortar and the development of damage in the latter. When concrete is exposed to high temperature, as is the case during fire, the failure mode is thermal spalling. In order to improve the prediction of the stresses involved in this failure Ortiz’s model is extended to account for the effects of high temperature. Published experimental results for uniaxial and biaxial compression at high temperatures are used to calibrate the temperature dependence of some of the material properties. The transient creep strain is accounted for by modifying the constrained thermal strain. The stress analysis is coupled with hygro-thermal analysis of heat, mass transfer and pore pressure build-up. The effect of pore pressure on the damage evolution is modeled by applying a body force in the stress analysis module proportional to the pressure gradient. A numerical example of concrete under fire is solved and the computed results are discussed. Spalling is predicted when the damage variable reaches its maximum value of unity. The predicted depth and time of spalling for a range of variation of permeability and initial liquid water content are presented. They are in good agreement with published experimental results.     

三种热喷涂涂层耐磨性能的研究

通过采用平稳加载往复滑动和动态加载冲击划痕 2种试验条件 ,研究了以钴基合金为重点的 3种热喷涂涂层的耐磨性 ,并初步探讨了其磨损机理 .结果表明 :3种涂层在滑动摩擦过程中的磨损机制为微切削和犁削 ;在冲击划痕条件下材料流失方式则以凿削和断裂为主 .试验结果证实 ,热喷涂涂层的耐磨性不仅与其宏观硬度有关 ,还与涂层的塑性、脆性及内聚强度密切相关     

Micromechanics-based thermoelastic model for functionally graded particulate materials with particle interactions

Thermoelastic behavior of functionally graded particulate materials is investigated with a micromechanical approach. Based on a special representative volume element constructed to represent the graded microstructure of a macroscopic material point, the relation between the averaged strains of the particle and matrix phases is derived with pair-wise particle interactions, and a set of governing equations for the thermoelastic behavior of functionally graded materials is presented. The effective coefficient of thermal expansion at a material point is solved through the overall averaged strain of two phases induced by temperature change under the stress-free condition, and is shown to exhibit a weak anisotropy due to the particle interactions within the graded microstructure. When the material gradient is eliminated, the proposed model predicts the effective coefficient of thermal expansion for uniform composites as expected. If the particle interactions are disregarded, the proposed model recovers the Kerner model. The proposed semi-analytical scheme is consistent and general, and can handle any thermal loading variation. As examples, the thermal stress distributions of graded thermal barrier coatings are solved for two types of thermal loading: uniform temperature change and steady-state heat conduction in the gradation direction.     

钢筋混凝土梁受弯破坏过程的细观数值模拟研究

在细观层次上将混凝土视为由粗骨料、硬化水泥砂浆及界面粘结带组成的三相非均质复合材料,能够较好地模拟混凝土加载时的裂缝扩展过程和分布规律。本文采用细观刚体弹簧元法模拟了钢筋混凝土梁的弯曲受力性能和破坏过程,加载方式采用两点对称加载。数值计算得到了钢筋混凝土梁的破坏形态和荷载一变形曲线,并分析了受力过程中纵向钢筋的应力变化。与试验结果对比表明,细观刚体弹簧元法可以有效模拟钢筋混凝土梁的裂缝开展过程、破坏形态和荷载一变形响应。     

受拉钢筋混凝土构件破坏过程的数值模拟

采用三维材料破坏过程分析MFPA3D系统,对钢筋混凝土构件轴心受拉条件下的受力、变形与内部裂纹萌生、扩展及最终破坏全过程进行了数值试验研究。数值模型中引入统计分布函数反映了混凝土的非均匀性影响,并采用具有残余强度的弹性损伤本构模型及其破坏单元材料性质退化方法,利用位移加载方式对钢筋混凝土构件实施拉伸加载。通过对钢筋、素混凝土方形体以及钢筋混凝土方形柱体构件在拉伸作用下破坏过程的数值试验,分析了钢筋与混凝土两种材料之间的相互作用、约束机理和破坏机理。数值试验成果对于深入了解钢筋和混凝土的联合受力规律和钢筋在开裂前后对整体钢筋混凝土结构的作用机制有参考价值。