FEM simulation of TBC failure in a model system

In order to study the behavior of the complex failure mechanisms in thermal barrier coatings on turbine blades, a simplified model system is used to reduce the number of system parameters. The artificial system consists of a bond-coat material (fast creeping Fecralloy or slow creeping MA956) as the substrate with a Y2O3 partially stabilized plasma sprayed zircon oxide TBC on top and a TGO between the two layers. A 2-dimensional FEM simulation was developed to calculate the growth stress inside the simplified coating system. The simulation permits the study of failure mechanisms by identifying compression and tension areas which are established by the growth of the oxide layer. This provides an insight into the possible crack paths in the coating and it allows to draw conclusions for optimizing real thermal barrier coating systems.