Rolf W. Steinbrech

Comprehensive microstructural characterization and predictive property modeling of plasma-sprayed zirconia coatings

Quantitative microstructure characterization to better understand processing-microstructure-property correlations is of considerable interest in plasma sprayed coating research. This paper quantifies, by means of small-angle neutron scattering (SANS) data, microstructure (porosity, opening dimensions, orientation and morphologies) in plasma sprayed partially-stabilized zirconia (PSZ) coatings, primarily used as thermal barrier coatings. We report on the investigation of the influence of feedstock characteristics on microstructure and establish its influence on the resultant thermal and mechanical properties. The microstructural parameters determined by SANS studies are then assembled into a preliminary model to develop a predictive capability for estimating the properties of these coatings. Thermal conductivity and elastic modulus were predicted using finite element analysis and ultimately compared to experimental values.  2003 Acta Materialia Inc. Published by Elsevier Science Ltd. All rights reserved.

Determination of the Stress-Dependent Stiffness of Plasma-Sprayed Thermal Barrier Coatings using Depth-Sensitive Indentation

The elastic response of atmospheric plasma-sprayed coatings was investigated using Vickers and spherical indenter geometries. In both cases a strong dependency of the stiffness on the applied load (indentation depth) was observed. The stiffness of the coatings decreased with increasing load for a Vickers indenter, whereas it increased for a spherical indenter. This contrary behavior was related to the relative crack density in the deformed volume and to the stress dependence of the stiffness due to crack closure. The effect of annealing on the stiffness was quantified for both tip geometries. The heat treatment yielded additional information on the relationship between the indentation data and the microstructural defects. From the results it was concluded that the stiffness measured using a sharp indenter and small load reflected the elastic behavior of single spraying splats. With the relatively large spherical indenter, the average global stiffness of the thermal barrier coating was measured even at small loads. From the data obtained using the spherical indenter, a compressive stress-strain curve was suggested. Furthermore, values of the apparent crack density and yield strength were determined from the indentation tests.

Cyclic fatigue in monolithic alumina : mechanisms for crack advance promoted by frictional wear of grain bridges

The microstructural basis of cyclic fatigue-crack propagation in monolithic alumina has been investigated experimentally and theoretically. A true cyclic fatigue effect has been verified, distinct from environmentally assisted slow crack growth (static fatigue). Microstructures with smaller grain sizes were found to promote faster crack-growth rates; growth rates were also increased at higher load ratios (i.e. ratio of minimum to maximum applied loads). Using in situ crack-path analysis performed on a tensile loading stage mounted in the scanning electron microscope, grain bridging was observed to be the primary source of toughening by crack-tip shielding. In fact, crack advance under cyclic fatigue appeared to result from a decrease in the shielding capacity of these bridges commensurate with oscillatory loading. It is proposed that the primary source of this degradation is frictional wear at the boundaries of the bridging grains, consistent with recently proposed bridging/degradation models, and as seen via fractographic and in situ analyses; specifically, load versus crack-openingdisplacement hysteresis loops can be measured and related to the irreversible energy losses corresponding to this phenomenon.

Mechanical properties of coated materials and multi-layered composites determined using bending methods

Relationships are presented to analyse the mechanical properties of multi-layered composites from experimental data of bending tests permitting a calculation of the modulus of rupture (MOR) for the failure of a particular layer within the composite. The proposed equations can also be used to determine the unknown elastic modulus or thickness for a layer within a multi-layered composite, if the respective properties of all other layers are known. Special consideration is given to the influence of coatings on substrate fracture.

Crack propagation studies of thermal barrier coatings under bending

Abstract The trends recently observed in crack propagation studies under bending for thermal barrier coatings (TBCs) in power plant application are highlighted in this paper. These studies described were performed with plasma sprayed zirconia bonded by a MCrAlY layer to Ni-base superalloy. Such thermal barrier composites are currently considered as candidate materials for advanced stationary gas turbine components. The crack propagation behaviour of the ceramic thermal barrier coatings (TBCs) at room temperature, in as received and oxidized conditions reveals that cracks grow linearly in the TBC with increase in bending load until about the yield point of the superalloy is reached. Approaching the interface between the ceramic layer and the bond coat, a high threshold load is required to propagate the crack further into the bond coat. Once the threshold is surpassed, the crack grows rapidly into the brittle bond coat without an appreciable increase in the load. At a temperature of 800°C, the crack is found to propagate only in the TBC (ceramic layer), as the ductile bond coat offers an attractive sink for stress relaxation. Effects of bond coat oxidation on crack propagation in the interface regime have been examined and are discussed. ©

Determination of the interfacial fracture energies of cathodes and glass ceramic sealants in a planar solid-oxide fuel cell design

A notched bimaterial bar bend test was applied to identify weak interfaces that influence the thermomechanical performance of solid-oxide fuel cell (SOFC) stacks with planar design. The experiments were focused on the weakest interface of the multilayered cells and on the rigid glass ceramic sealants between metallic interconnects of SOFC stacks. The fracture energies of these interfaces were determined. To test interfaces within the cells, they were glued to steel strips, and the notched cell was used as a stiffener in the test. The weakest part of the cells with composite cathodes was the interface between the functional part of the cathode and the remaining current collector. Values for the interfacial fracture energies of composite cathodes both freshly prepared and after aging were determined. Taking advantage of the crack extension within the anode from the notch-tip to the interface, the fracture energy of the oxidized and reduced anodes was calculated. Sandwich specimens with glass ceramic between the interconnect steel were used to determine the fracture energies for different glass ceramic-steel interfaces. Different combinations of ferritic steel and glass ceramic were tested. The fracture path developed partly along the interface and partly in the glass ceramic, which did not influence the fracture energy. However, a significant improvement of the fracture energy with annealing time was found.

Influence of sample deformation and porosity on mechanical properties by instrumented microindentation technique

General equations are derived for evaluating the contributions of the non-penetration displacements to the apparent Youngs modulus and hardness measured in an instrumented microindentation test. An idealized disk model is proposed to simulate the roles of porosity and sample displacements in determining Youngs modulus and hardness from the indentation curve. The model is then applied to experimental data obtained from the indentation tests completed with separated and bonded yttria-stabilized zirconia (YSZ) thermal barrier coating layers. It is shown that in an instrumented microindentation test of a thin material plate, large scatter in the mechanical properties may originate from non-penetration displacements which usually increase with decreasing sample thickness. Predictions are also made for the apparent E-H values and show reasonable agreement with the measured data.

R-Curve Behavior of Ceramics

The demand for ceramics with improved toughness and flaw tolerance has focused attention in recent years on R-curve behavior which is characterized by an increase in crack resistance (toughness) with crack extension. In a brief review, R-curves of various oxide and non-oxide ceramics are shown in order to demonstrate the potential of the effect and to outline underlying toughening mechanisms.

Indentation strength method to determine the fracture toughness of La0.58Sr0.4Co0.2Fe0.8O3-δ and Ba0.5Sr0.5Co0.8Fe0.2O3-δ

The temperature-dependent fracture toughness of brittle ceramics can be conveniently assessed from bending tests of specimens with defined cracks introduced by indentation. However, the validity of this indentation strength in bending method (ISM) depends critically on the correct consideration of the residual stress induced by the indentation process. The ISM has been applied to La0.58Sr0.4Co0.2Fe0.8O3-δ (LSCF) and, for comparison, on Ba0.5Sr0.5Co0.2Fe0.8O3-δ (BSCF) perovskite. LSCF with rhombohedral phase exhibits ferro-elastic behavior at ambient temperature, whereas BSCF deforms linear-elastically. Pre-indented specimens of both perovskites were fractured at room temperature in biaxial bending, some of them after an additional annealing step. The fracture toughness values of BSCF match reasonably well when determined with equations which consider the presence or absence of residual indentation stress. Interestingly, annealing has little influence on the apparent toughness results obtained for rhombohedral LSCF, which appears to be related with stress relaxation by ferro-elastic deformation.

Strain analysis of plasma sprayed thermal barrier coatings under mechanical stress

The stiffness of air plasma sprayed (APS) thermal barrier coatings (TBCs) was determined from bending experiments combining strain analysis on a microstructural level with macroscopic mechanical parameters. Tests were performed with freestanding and attached TBCs, the latter either loaded in tension or in compression. Relationships are derived, which describe the TBC stiffness in a multilayer composite (attached TBC) and for a bimodular material that possess a lower stiffness in tension than in compression (stand-alone TBC). The increase of in-plane stiffness with increasing compressive stress emphasizes the importance of the spraying defects for the elastic response of the coating.