Understanding the Failure Mechanism of Thermal Barrier Coatings Considering the Local Bulge at the Interface between YSZ Ceramic and Bond Layer

The TC/BC interface morphology in APS TBC is one of the important factors leading to crack propagation and coating failure. Long cracks are found near the bulge on the TC/BC interface. In this study, the TBC model with the bulge on the interface is developed to explore the influence of the bulge on the coating failure. Dynamic TGO growth and crack propagation are considered in the model. The effects of the bulge on the stress state and crack propagation in the ceramic layer are examined. Moreover, the effects of the distribution and number of bulges are also investigated. The results show that the bulge on the interface results in the redistribution of local stress. The early cracking of the ceramic layer occurs near the top of the bulge. One bulge near the peak or valley of the interface leads to a coating life reduction of about 75% compared with that without a bulge. The increase in the number of bulges further decreases the coating life, which is independent of the bulge location. The results in this work indicate that a smooth TC/BC interface obtained by some possible surface treatments may be an optional scenario for improving coating life.

Performance of Exterior Wood Coatings in Temperate Climates

Wood used in exposed exterior applications degrades and changes color due to weathering. Expanded use of mass timber is resulting in architects increasingly designing structures with wood in exterior exposure. Coatings can reduce the effects of weathering and prolong the visual characteristics of wood. However, coating performance depends on a variety of factors including the blend of resins, oils, pigments, and binders. Coating manufacturers often claim superior performance for products, but data directly comparing different coatings on different species is rarely publicly available. Premature coating failure increases long-term building maintenance expense while potentially enhancing biological degradation and reducing service life. This study compares the performance of 12 exterior wood coatings on 5 wood species. Performance was evaluated according to changes in the components in the International Commission on Illumination (CIE) L*a*b* color space of images taken at 6-month intervals over 18 months of the wood samples. The analysis was performed using Welch’s ANOVA, Games–Howell pairwise comparisons tests, and a clustering procedure using distances between each pair of groups means for the 18 months ΔL*, Δa*, Δb* values. Most of the coatings lost their protective effects within 1 year of exposure due to combinations of biological and ultraviolet radiation (UV) degradation illustrating the difficulty of protecting timber in exterior exposures. This study provides a guide for users wishing to specify coatings for exposed wood in mass timber structures.

The Oxidation Behaviour and Notch Wear Formation of TiAlN Coated Tools Using Different Oxidation Techniques

This paper proposes a novel approach to assessing oxidation behavior of TiAlN coatings with defined stoichiometry on the rake and flank surfaces. This is based on the multi-parametric comparison of the oxidation effects detected on the coatings’ surfaces resulting from static diffusion couple tests. In this experimental study the diffusion couples consisting of Ti-based and Ni-based alloys and coated TiAlN cutting inserts are tested, respectively. The optimum oxidation temperature was determined by annealing the selected TiAlN coating in a high temperature chamber at temperatures: 700 °C, 800 °C, 900 °C and 1000 °C in air. Concurrently, the mass change and corresponding thickness of the Al2O3 oxidized layer were measured and computed. The comparison of oxides produced covers the surface morphologies, chemical elements and phases which were analyzed by means of SEM (scanning electron microscope), EDS (energy dispersive spectroscopy) and XRD (X-ray diffraction techniques). Additionally, scratch tests were performed to assess the penetration depth down to the substrate and coating failure mechanism after oxidation in diffusion couples. An acceptable similarity of Al2O3 films formed on the TiAlN coating surfaces in diffusion couples and machining processes was established.

Experiment Study on Topological Characteristics of Sandstone Coating by Micro CT

The pore structure is an important factor of tunnel coating failure, cracking and water leakage. Some investigations on the statistical law of pores and pore networks have been conducted, but little quantitative analysis is observed on topology structure of the pore network, and even the pore structure of sandstone is complex and cross-scale distributed. Therefore, it is of theoretical and engineering significance to quantitatively characterize the connectivity of the pore network in sandstone. This study proposes a new complex network theory to analyze the three-dimensional nature of pore network structure in sandstone. The topological network structure, such as clustering degree, average path length and the module, which cannot be analyzed by traditional coordination number and fractal dimension methods, is analyzed. Numerical simulation results show that a scale-free network model is more suitable for describing the sandstone pore network than random models. The pore network of sandstone has good uniformity. The connectivity of sandstone pore networks has great potential for permeability enhancement. Therefore, this new method provides a way to deeply understand the pore connectivity characteristics of sandstone and to explore the distribution of crack grids in the arch of tunnel coatings.

Mechanical Integrity of Thermal Barrier Coatings: Coating Development and Micromechanics

To protect the copper liners of liquid-fuel rocket combustion chambers, a thermal barrier coating can be applied. Previously, a new metallic coating system was developed, consisting of a NiCuCrAl bond-coat and a Rene 80 top-coat, applied with high velocity oxyfuel spray (HVOF). The coatings are tested in laser cycling experiments to develop a detailed failure model, and critical loads for coating failure were defined. In this work, a coating system is designed for a generic engine to demonstrate the benefits of TBCs in rocket engines, and the mechanical loads and possible coating failure are analysed. Finally, the coatings are tested in a hypersonic wind tunnel with surface temperatures of 1350 K and above, where no coating failure was observed. Furthermore, cyclic experiments with a subscale combustion chamber were carried out. With a diffusion heat treatment, no large-scale coating delamination was observed, but the coating cracked vertically due to large cooling-induced stresses. These cracks are inevitable in rocket engines due to the very large thermal-strain differences between hot coating and cooled substrate. It is supposed that the cracks can be tolerated in rocket-engine application.

PREPARATION AND CHARACTERISTICS OF CO-DOPED HYDROXYAPATITE BIOMIMETIC COATINGS ON PRETREATED Ti6Al4V ALLOY

In this study, [Formula: see text] co-doped and pure hydroxyapatites (HAp) were coated on rough surfaces of Ti6Al4V plates by biomimetic method. Prepared samples were investigated with SEM, EDS, FTIR, XRD and ICP. Furthermore, mechanical scratch tests, profilometer tests and in vitro cell studies were carried out. In order to explore the antibacterial characteristics of the coating, the survival rate of a bacteria named Staphylococcus epidermidis was determined. Structural investigations showed that HAp nucleation began four days after the immersion, expectedly nucleation developed collaterally with the incubation period and co-dopants had considerable effect on surface characteristics. Besides, the pretreatment procedure and dopants had notable impact on mechanical qualifications of the coatings. The critical load values obtained for coating failure were detected above 100[Formula: see text]mN in all types of coatings (max. critical load was obtained from 0.3[Formula: see text]mM co-doped coatings). Cancerous bone cells (SaOS-2) on prepared coatings were evaluated in terms of biological properties. 0.1-C7 and 0.3-C7 exhibited highest reduction percentage among all co-doped samples. Further increase in dopants concentrations up to 0.5[Formula: see text]mM lead to increase in toxicity and decrease in cell proliferation. Antibacterial test results showed the most antibacterial samples were 0.1-C7 and 0.3-C7, the results conformed with cell culture findings.

Femtosecond Laser-Induced Damage Characterization of Multilayer Dielectric Coatings

The laser-induced damage threshold (LIDT) of optical components is one of the major constraints in developing high-power ultrafast laser systems. Multi-layer dielectric (MLD) coatings-based optical components are key parts of high-power laser systems because of their high damage resistance. Therefore, understanding and characterizing the laser-induced damage of MLD coatings are of paramount importance for developing ultrahigh-intensity laser systems. In this article, we overview the possible femtosecond laser damage mechanisms through damage morphologies in various MLD optical coatings tested in our facility. To evaluate the major contributions to the coating failure, different LIDT test methods (R-on-1, ISO S-on-1 and Raster Scan) were carried out for a high reflective hybrid Ta2O5/HfO2/SiO2 MLD mirror coating at a pulse duration of 37 fs. Different LIDT test methods were compared due to the fact that each test method exposes the different underlying damage mechanisms. For instance, the ISO S-on-1 test at a higher number of laser pulses can bring out the fatigue effects, whereas the Raster Scan method can reveal the non-uniform defect clusters in the optical coating. The measured LIDT values on the sample surface for the tested coating in three test methods are 1.1 J/cm2 (R-on-1), 0.9 J/cm2 (100k-on-1) and 0.6 J/cm2 (Raster Scan) at an angle of incidence of 45 deg. The presented results reveal that the performance of the tested sample is limited by coating defects rather than fatigue effects. Hence, the Raster Scan method is found to be most accurate for the tested coating in evaluating the damage threshold for practical applications. Importantly, this study demonstrates that the testing of different LIDT test protocols is necessary in femtosecond regime to assess the key mechanisms to the coating failure.