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A typical coating microstructure (Figure 4.2.4) was imported into the OOF code, digitized for thermal analysis and then subjected to a temperature change of 1000°C (1832°F). The calculated global stresses were similar to that obtained from equation 1 [Figure 4.2.2]. Typical EBC Digitized Microstructure Figure 4.2.4: EBC coating microstructure and digitized image for OOF analysis In addition to the calculation of the residual stresses, the elements in the OOF code are designed to fail under a Griffith-like strain energy based criterion. The elements crack when the required surface energy can be supplied by the stored strain energy per crack extension (∆L), i.e., Intermediate Layer Bond Coat 100 μm 1 σ elemε elem A / ∆L ≥ 2γ 2 ij ij elem (4.2) where γ is the surface energy of the cracked interface. The analysis involves the following steps: a. Thermal and mechanical loads are applied and the microstructure is equilibrated to determine stress/strain distribution. b. The energy balance is computed and if an element satisfies the energy criterion for cracking, the stiffness of the element is set to zero. c. The microstructure is re-equilibrated and the stress distribution is re-calculated. d. The procedure is repeated until no more elements mutate or one or more cracks become unstable, causing fracture into two or more fragments. A parametric study was undertaken to develop an understanding of the effects of material properties on residual stresses and crack initiation and propagation using simple geometries. The simulation results indicated that crack propagation and arrest were strongly dependent on relative surface energies and residual stresses. Further, it was found that incorporating a low modulus interlayer between Si3N4 and silicon could help in isolating the flaws in the coating from the pre-existing flaws in Si3N4. As predicted by the OOF approach, it was observed that a low modulus oxide inter-layer between Si3N4 and Si successfully solved the problem of substrate strength retention. The interlayer was applied using a dip coating process and the Si layer was applied by CVD. The interlayer coating was found to help retain the strength of Si3N4 as is shown in 86PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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