A theoretical model for the study of thermal fracture of functionally graded thermal barrier coatings with a system of edge and internal cracks

Abstract

The problem of fracture of functionally graded coatings (FGCs) on a homogeneous substrate (a semi-infinite medium) is investigated under the influence of thermal and/or mechanical loads (e.g. a heat flux, residual thermal stresses caused by cooling-heating, tension). These loads reflect the most important cases, which arise during the exploitation of FGC structures. The FGC contains pre-existing systems of cracks, such as edge, internal and interface cracks. The mathematical description of the model is based on singular integral equations. The properties of the FGC are continuous functions of the thickness coordinate. Furthermore, the non-homogeneity of the functionally graded material is revealed in the form of corresponding inhomogeneous traction distributions on the surfaces of cracks. This method is approximate and used with the assumption, that the gradation of material properties of the FGC with the depth of the layer is not abrupt. The influence of residual stresses caused by temperature changes on ΔT (e.g. cooling from operating temperatures) is investigated in detail. Different crack patterns (which are reported in experiments and available in the literature) are studied by carrying out numerical experiments with respect to stress intensity factors and fracture angles (a deviation of cracks from the initial direction of propagation). The proposed model in combination with a detailed parametric analysis can help to optimize FGCs in order to improve the fracture resistance of FGC/homogeneous structures.