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Eriksson, Robert
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Publications (10 of 35) Show all publications
Jonnalagadda, K. P., Eriksson, R., Li, X.-H. & Peng, R. L. (2019). Fatigue life prediction of thermal barrier coatings using a simplified crack growth model. Journal of the European Ceramic Society, 39(5), 1869-1876
Open this publication in new window or tab >>Fatigue life prediction of thermal barrier coatings using a simplified crack growth model
2019 (English)In: Journal of the European Ceramic Society, ISSN 0955-2219, E-ISSN 1873-619X, Vol. 39, no 5, p. 1869-1876Article in journal (Refereed) Published
Abstract [en]

Models that can predict the life of thermal barrier coatings (TBCs) during thermal cycling fatigue (TCF) tests are highly desirable. The present work focuses on developing and validating a simplified model based on the relation between the energy release rate and the TCF cycles to failure. The model accounts for stresses due to thermal mismatch, influence of sintering, and the growth of TGO (alumina and other non-protective oxides). The experimental investigation of TBCs included; 1) TCF tests at maximum temperatures of 1050 °C, 1100 °C, 1150 °C and a minimum temperature of 100 °C with 1 h and 5 h (1100 °C) hold times. 2) Isothermal oxidation tests at 900, 1000 and 1100 °C for times up to 8000 h. The model was calibrated and validated with the experimental results. It has been shown that the model is able to predict the TCF life and effect of hold time with good accuracy.

Keywords
Thermal barrier coatings, Thermal cycling fatigue, Life prediction model, Energy release rate
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:liu:diva-154780 (URN)10.1016/j.jeurceramsoc.2018.12.046 (DOI)000459950700016 ()
Note

Funding agencies: Vinnova in Sweden

Available from: 2019-02-26 Created: 2019-02-26 Last updated: 2019-03-20
Jonnalagadda, K. P., Eriksson, R., Li, X.-H. & Peng, R. L. (2019). Thermal barrier coatings: Life model development and validation. Surface & Coatings Technology, 362, 293-301
Open this publication in new window or tab >>Thermal barrier coatings: Life model development and validation
2019 (English)In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 362, p. 293-301Article in journal (Refereed) Published
Abstract [en]

The failure of thermal barrier coatings (TBCs) during thermal cyclic fatigue (TCF) tests depends mainly on the thermal mismatch between the coating and the substrate, the thermally grown oxides (TGO) at the top coat-bond coat interface, and the sintering of the top coat. Understanding the interplay between these factors is essential for developing a life model. The present work focuses on further development of a previously established fracture mechanics based life model and its validation by comparing with the experimental results. The life model makes use of a Paris' law type equation to estimate the cycles to failure based on micro-crack growth. The fitting parameters for the Paris' law were obtained from the experimentally measured crack lengths after the interruption of TCF tests at different cycles. An alternative approach to obtain the fitting parameters through video monitoring was also discussed. It is shown that regardless of the approach to obtain the fitting parameters, the life model in its current form is able to predict the TCF life at different temperatures with reasonable accuracy. However, at very high temperatures (1150 °C) the predictive capabilities of the model appeared to be poor.

Keywords
Thermal barrier coatings, Thermal cyclic fatigue, Life modeling, Life prediction
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:liu:diva-154779 (URN)10.1016/j.surfcoat.2019.01.117 (DOI)000461526400035 ()
Note

Funding agencies: VINNOVA in Sweden

Available from: 2019-02-26 Created: 2019-02-26 Last updated: 2019-04-03
Jonnalagadda, K. P., Eriksson, R., Yuan, K., Li, X.-H., Ji, X., Yu, Y. & Peng, R. L. (2017). A Study of Damage Evolution in High Purity Nano TBCs During Thermal Cycling: A Fracture Mechanics Based modeling approach.. In: ASME Turbine Expo: . Paper presented at ASME Turbine Expo 2017, June 25-29, 2017, North Carolina, USA (pp. 2889-2899). Elsevier, 37, Article ID 8.
Open this publication in new window or tab >>A Study of Damage Evolution in High Purity Nano TBCs During Thermal Cycling: A Fracture Mechanics Based modeling approach.
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2017 (English)In: ASME Turbine Expo, Elsevier, 2017, Vol. 37, p. 2889-2899, article id 8Conference paper, Published paper (Refereed)
Abstract [en]

This work concerns the study of damage evolution in a newly developed high purity nano 8YSZ thermal barrier coating during thermal cyclic fatigue tests (TCF). TCF tests were conducted between 100 °C–1100 °C with a hold time of 1 h at 1100 °C, first till failure and later for interrupted tests. Cross section analysis along the diameter of the interrupted test samples revealed a mixed-type failure and that the most of the damage occurred towards the end of the coating’s life. To understand the most likely crack growth mechanism leading to failure, different crack growth paths have been modelled using finite element analysis. Crack growing from an existing defect in the top coat towards the top coat/TGO interface has been identified as the most likely mechanism. Estimated damage by the model could predict the rapid increase in the damage towards the end of the coating’s life.

Place, publisher, year, edition, pages
Elsevier, 2017
Keywords
Thermal cyclic fatigue, High purity nano YSZ, Crack growth modelling, Damage evolution
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-142310 (URN)10.1016/j.jeurceramsoc.2017.02.054 (DOI)2-s2.0-85014154522 (Scopus ID)
Conference
ASME Turbine Expo 2017, June 25-29, 2017, North Carolina, USA
Available from: 2017-10-25 Created: 2017-10-25 Last updated: 2017-11-21Bibliographically approved
Eriksson, R., Chen, Z. & Jonnalagadda, K. P. (2017). Bending Fatigue of Thermal Barrier Coatings. Journal of engineering for gas turbines and power, 139(12), 122101-1-122101-6
Open this publication in new window or tab >>Bending Fatigue of Thermal Barrier Coatings
2017 (English)In: Journal of engineering for gas turbines and power, ISSN 0742-4795, E-ISSN 1528-8919, Vol. 139, no 12, p. 122101-1-122101-6Article in journal (Refereed) Published
Abstract [en]

Thermal barrier coatings (TBCs) are ceramic coatings used in gas turbines to lower the base metal temperature. During operation, the TBC may fail through, for example, fatigue. In this study, a TBC system deposited on a Ni-base alloy was tested in tensile bending fatigue. The TBC system was tested as-sprayed and oxidized, and two load levels were used. After interrupting the tests, at 10,000–50,000 cycles, the TBC tested at the lower load had extensive delamination damage, whereas the TBC tested at the higher load was relatively undamaged. At the higher load, the TBC formed vertical cracks which relieved the stresses in the TBC and retarded delamination damage. A finite element (FE) analysis was used to establish a likely vertical crack configuration (spacing and depth), and it could be confirmed that the corresponding stress drop in the TBC should prohibit delamination damage at the higher load.

Place, publisher, year, edition, pages
ASME Press, 2017
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-142274 (URN)10.1115/1.4037587 (DOI)000415791400010 ()2-s2.0-85029559590 (Scopus ID)
Available from: 2017-10-24 Created: 2017-10-24 Last updated: 2017-12-12Bibliographically approved
Jonnalagadda, K. P., Eriksson, R., Yuan, K., Li, X.-H., Ji, X., Yu, Y. & Peng, R. L. (2017). Comparison of Damage Evolution During Thermal Cycling in a High Purity Nano and Conventional Thermal Barrier Coating. Surface & Coatings Technology, 332, 47-56
Open this publication in new window or tab >>Comparison of Damage Evolution During Thermal Cycling in a High Purity Nano and Conventional Thermal Barrier Coating
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2017 (English)In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 332, p. 47-56Article in journal (Refereed) Published
Abstract [en]

Thermal barrier coatings (TBCs), consisting of a ceramic top coat and a metallic bond coat, offer resistance against high temperature degradation of turbine components. Cyclic oxidation of the bond coat, thermal stresses due to their thermal mismatches during cyclic operations, and sintering of the top coat are considered to be the common ways by which thermal barrier coatings fail. To reduce sintering, a nano structured high purity yttria stabilized zirconia (YSZ) was developed. The focus of this work is to compare the damage development of such high purity nano YSZ TBC during thermal cycling with a conventional YSZ TBC. Thermal cyclic fatigue (TCF) tests were conducted on both the TBC systems between 100 °C and 1100 °C with a 1 h hold time at 1100 °C. TCF test results showed that conventional YSZ TBC exhibited much higher life compared to the high purity nano YSZ TBC. The difference in the lifetime is explained by the use of microstructural investigations, crack length measurements along the cross-section and the difference in the elastic modulus. Furthermore, stress intensity factors were calculated in order to understand the difference(s) in the damage development between the two TBC systems.

Place, publisher, year, edition, pages
Elsevier, 2017
Keywords
High purity nano, damage evolution, thermal cycling fatigue, crack length measurement, conventional TBC
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-142311 (URN)10.1016/j.surfcoat.2017.09.069 (DOI)000418968100007 ()2-s2.0-85030751243 (Scopus ID)
Note

Funding agencies: Vinnova in Sweden [2015-06870]

Available from: 2017-10-25 Created: 2017-10-25 Last updated: 2019-02-26Bibliographically approved
Calmunger, M., Eriksson, R., Chai, G., Johansson, S. & Moverare, J. (2017). Influence of Cyclic Oxidation in Moist Air on Surface Oxidation-Affected Zones. In: : . Paper presented at EUROMAT17, Thessaloniki 17-21 September 2017,Greece (pp. 1-1).
Open this publication in new window or tab >>Influence of Cyclic Oxidation in Moist Air on Surface Oxidation-Affected Zones
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2017 (English)Conference paper, Oral presentation with published abstract (Refereed)
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-143972 (URN)
Conference
EUROMAT17, Thessaloniki 17-21 September 2017,Greece
Available from: 2018-01-01 Created: 2018-01-01 Last updated: 2018-01-16Bibliographically approved
Calmunger, M., Eriksson, R., Chai, G., Johansson, S., Högberg, J. & Moverare, J. (2017). Local Surface Phase Stability During Cyclic Oxidation Process. Paper presented at THERMEC'16, May 30 - June 3, 2016, Graz, Austria. Materials Science Forum, 879, 855-860
Open this publication in new window or tab >>Local Surface Phase Stability During Cyclic Oxidation Process
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2017 (English)In: Materials Science Forum, ISSN 0255-5476, E-ISSN 1662-9752, Vol. 879, p. 855-860Article in journal (Refereed) Published
Place, publisher, year, edition, pages
Trans Tech Publications, 2017
Keywords
Austenitic stainless steels, thermal cycling, corrosion, surface phase stability
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-129244 (URN)10.4028/www.scientific.net/MSF.879.855 (DOI)
Conference
THERMEC'16, May 30 - June 3, 2016, Graz, Austria
Available from: 2016-06-14 Created: 2016-06-14 Last updated: 2017-11-28
Gupta, M., Eriksson, R., Sand, U. & Nylén, P. (2015). A Diffusion-based Oxide Layer Growth Model Using Real Interface Roughness in Thermal Barrier Coatings for Lifetime Assessment. Paper presented at 2014 International Conference on Surfaces, Coatings and Nanostructured Materials (NANOSMAT) - Europe, Dublin, Ireland, 8–11 September 2014. Surface & Coatings Technology, 271, 181-191
Open this publication in new window or tab >>A Diffusion-based Oxide Layer Growth Model Using Real Interface Roughness in Thermal Barrier Coatings for Lifetime Assessment
2015 (English)In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 271, p. 181-191Article in journal (Refereed) Published
Abstract [en]

The development of thermo-mechanical stresses during thermal cycling can lead to the formation of detrimental cracks in Atmospheric Plasma Sprayed (APS) Thermal Barrier Coatings systems (TBCs). These stresses are significantly increased by the formation of a Thermally Grown Oxide (TGO) layer that forms through the oxidation of mainly aluminium in the bondcoat layer of the TBC. As shown in previous work done by the authors, the topcoat–bondcoat interface roughness plays a major role in the development of the stress profile in the topcoat and significantly affects the lifetime of TBCs. This roughness profile varies as the TGO layer grows and changes the stress profile in the topcoat leading to crack propagation and thus failure.

In this work, a two-dimensional TGO growth model is presented, based on oxygen and aluminium diffusion–reaction equations, using real interface profiles extracted from cross-section micrographs. The model was first validated by comparing the TGO profiles artificially created by the model to thermally cycled specimens with varying interface roughness. Thereafter, stress profiles in the TBC system, before and after the TGO layer growth, were estimated using a finite element modelling model described in previous work done by the authors. Three experimental specimens consisting of the same chemistry but with different topcoat–bondcoat interface roughness were studied by the models and the stress state was compared to the lifetimes measured experimentally. The combination of the two models described in this work was shown to be an effective approach to assess the stress behaviour and lifetime of TBCs in a comparative way.

Place, publisher, year, edition, pages
Elsevier, 2015
Keywords
Thermal Barrier Coatings (TBC);Thermally Grown Oxide (TGO);Lifetime;Thermo-mechanical stress state;Modelling;Interface roughness
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-114865 (URN)10.1016/j.surfcoat.2014.12.043 (DOI)000355349800028 ()
Conference
2014 International Conference on Surfaces, Coatings and Nanostructured Materials (NANOSMAT) - Europe, Dublin, Ireland, 8–11 September 2014
Available from: 2015-03-05 Created: 2015-03-05 Last updated: 2017-12-04Bibliographically approved
Eriksson, R., Yuan, K., Li, X.-H. & Peng, R. (2015). Corrosion of NiCoCrAIY Coatings and TBC Systems Subjected to Water Vapor and Sodium Sulfate. Journal of thermal spray technology (Print), 24(6), 953-964
Open this publication in new window or tab >>Corrosion of NiCoCrAIY Coatings and TBC Systems Subjected to Water Vapor and Sodium Sulfate
2015 (English)In: Journal of thermal spray technology (Print), ISSN 1059-9630, E-ISSN 1544-1016, Vol. 24, no 6, p. 953-964Article in journal (Refereed) Published
Abstract [en]

Thermal barrier coating (TBC) systems are commonly used in gas turbines for protection against high-temperature degradation. Penetration of the ceramic top coat by corrosive species may cause corrosion damage on the underlying NiCoCrAlY bond coat and cause failure of the TBC system. In the current study, four oxidation/corrosion conditions were tried: (i) lab air, (ii) water vapor, (iii) sodium sulfate deposited on the specimens, and (iv) water vapor + sodium sulfate. The test was done at 750 °C in a cyclic test rig with 48 h cycles. The corrosion damage was studied on NiCoCrAlY-coated specimens, thin APS TBC specimens, and thick APS TBC specimens. Water vapor was found to have very minor influence on the oxidation, while sodium sulfate increased the TGO thickness both for NiCoCrAlY specimens and TBC-coated specimens; the influence of the TBC thickness was found to be very small. Sodium sulfate promoted thicker TGO; more Cr-rich TGO; the formation of Y oxides, and internally, Y sulfides; pore formation in the coating as well as in the substrate; and the formation of a Cr-depleted zone in the substrate.

Place, publisher, year, edition, pages
Springer, 2015
Keywords
corrosion, cyclic furnace, sodium sulfate, thermal barrier coating, water vapor
National Category
Corrosion Engineering
Identifiers
urn:nbn:se:liu:diva-119690 (URN)10.1007/s11666-015-0253-z (DOI)000358965400007 ()
Available from: 2015-06-24 Created: 2015-06-24 Last updated: 2017-12-04
Eriksson, R., Gupta, M., Broitman, E., Jonnalagadda, K. P., Nylén, P. & Peng, R. (2015). Stresses and Cracking During Chromia-Spinel- NiO Cluster Formation in TBC Systems. Journal of thermal spray technology (Print), 24(6), 1002-1014
Open this publication in new window or tab >>Stresses and Cracking During Chromia-Spinel- NiO Cluster Formation in TBC Systems
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2015 (English)In: Journal of thermal spray technology (Print), ISSN 1059-9630, E-ISSN 1544-1016, Vol. 24, no 6, p. 1002-1014Article in journal (Refereed) Published
Abstract [en]

Thermal barrier coatings (TBC) are used in gas turbines to reduce the temperatures in the underlying substrate. There are several mechanisms that may cause the TBC to fail; one of them is cracking in the coating interface due to extensive oxidation. In the present study, the role of so called chromia-spinel-NiO (CSN) clusters in TBC failure was studied. Such clusters have previously been found to be prone to cracking. Finite element modeling was performed on a CSN cluster to find out at which stage of its formation it cracks and what the driving mechanisms of cracking are. The geometry of a cluster was obtained from micrographs and modeled as close as possible. Nanoindentation was performed on the cluster to get the correct Young’s moduli. The volumetric expansion associated with the formation of NiO was also included. It was found that the cracking of the CSN clusters is likely to occur during its last stage of formation as the last Ni-rich core oxidizes. Furthermore, it was shown that the volumetric expansion associated with the oxidation only plays a minor role and that the main reason for cracking is the high coefficient of thermal expansion of NiO.

Place, publisher, year, edition, pages
Springer, 2015
Keywords
chromia-spinel-NiO, failure mechnism, finite element modeling, oxide cluster, thermal barrier coating
National Category
Other Materials Engineering
Identifiers
urn:nbn:se:liu:diva-120423 (URN)10.1007/s11666-015-0270-y (DOI)000358965400012 ()
Available from: 2015-08-10 Created: 2015-08-10 Last updated: 2017-12-04
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