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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. An example of such an analysis is shown in Figure 6. The simulation results indicated that crack propagation and arrest were strongly dependent on relative surface energies and residual stresses. Further, it was found that using 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 is applied using a dip coating process and the Si layer is applied by CVD. The coating was found to help retain the strength of Si3N4 as is shown in figure 7. The two bars in figure 7a represent 35 μm and 70 μm thick silicon layers. The inter-layer approach has been used for Si thicknesses up to 100 μm with successful retention of baseline strength. Figure 7b shows a typical microstructure of the bond coat system. A well adhered gas tight top layer is expected to provide the steam protection required in the gas turbine environment. Intermediate Layer Thermal Stress in x-direction due to CTE mismatch Red elements are cracked Figure 6: Residual stresses and cracking in EBC coated substrates using OOF Silicon Silicon Nitride 148 Copyright © 2007 by ASME Top LayerPDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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