Simulation of foreign particle erosion-induced failure in thermal barrier coatings: A novel coupling plastic damage model of dual-horizon peridynamics and FEM

Abstract

The foreign particle erosion that the particles ingested into the gas turbine engine inlet or produced by the carbon deposits in the combustor could impact the surface of ceramic layer in thermal barrier coatings (TBCs) may cause the performance loss of TBCs and engine explosion in severe cases. Thus, it is important to study the foreign particle erosion-induced failure mechanism in thermal barrier coatings. To this end, we propose a coupling plastic damage model of dual-horizon peridynamics and FEM for foreign particle erosion-induced failure of TBCs. Dual-horizon peridynamics is used in the portions of areas that may exist significant plastic deformation and damage, meanwhile FEM is used in the remaining areas to minimize computing costs. The coupling plastic damage model is firstly validated by the ductile damage of the 2D asymmetrically notched specimen and 3D cylinder with the initial penny-shaped fracture. And then, the influences of the foreign particle shape, impact velocity and erosion angle on the erosion failure of TBCs are comprehensively investigated by the coupling plastic damage model. The numerical results are in quantitative and qualitative agreement with the existing experiment or the preceding numerical solution. Our numerical investigation confirms the need for developing the coupling plastic damage model in revealing the foreign particle erosion-induced failure process of TBCs.