Failure Behavior of Thermal Barrier Coatings Based on Acoustic Emission Technique
LI Xuehuan1, DI Yuelan2, WANG Haidou2, LI Guolu1, DONG Lihong2
1 School of Materials Science and Engineering,Hebei University of Technology, Tianjin 300130; 2 National Key Laboratory for Remanufacturing, Academy of Army Armored Forces, Beijing 100072
Abstract: Thermal barrier coatings (TBCs) have been widely used in gas turbines and aero engines,thanks to their excellent thermal insulation, wear and corrosion resistance. The failure of the thermal barrier coatings is usually unpredictable due to the complex internal structure of the TBC systems and the harsh service environment. Surface cracking and interface delaminating or spalling in TBC are bottlenecks which block the long-term service of TBCs, and premature spalling of TBCs causes the substrate to be exposed to gas with high temperature, which may lead to disastrous consequences. The most important and direct research method for the crack growth behavior of TBCs is to carry out the real-time nondestructive testing of the whole failure process under simulated actual working environment, which can provide the direct reference for the prediction of the life of the thermal barrier coating. Acoustic emission(AE) is a real-time nondestructive testing technique to track the failure process of TBCs, which can conti-nuously detect slight deformation and failure behavior in the interior of materials. Now, it has been widely used in the field of failure detection of TBCs. Nevertheless, there are many factors that lead to the failure of TBCs, including the complex failure mechanism, the variety of failure forms, and the randomness and irreversibility of acoustic emission signal itself. Therefore, the research on the whole process of detecting failure of TBCs by acoustic emission technique is not comprehensive enough. At present, the qualitative, quantitative and location analysis of the failure of TBCs has been realized through the parameter analysis and waveform analysis of acoustic emission technique, and the lifetime of TBCs can be predicted. Parameter analysis is a process in which several simplified waveform characteristic parameters are used to represent the characteristics of acoustic emission signals, namely the process of counting some feature parameters like energy, frequency and amplitude etc. The quantitative evaluation of the damage degree and the lifetime prediction of TBCs can be realized by parameters analysis of acoustic emission technique. Currently, the life expectancy of the TBCs is predicted from the perspectives of the continuous damage accumulation and the variation of a certain parameter. However, various life prediction models mainly based on empirical or semi-empirical formula from experimental results. With the development of TBCs and the deepening understanding of the failure mechanism of TBCs, the life prediction model is also constantly developing and improving. Waveform analysis is a signal processing method to obtain defect information by analyzing the time domain waveform or spectrum characteristic of acoustic emission signal. Theoretically, waveform analysis can give any needed information, therefore waveforms are the most accurate way to express the characteristics of acoustic emission sources. At present, through the transformation of acoustic emission waveform signal from time domain to frequency domain by wavelet transform, the damage mode identification and the acoustic emission source localization can be realized. This review gives a brief introduction of AE technique, summarizes the progress of parameters analysis and waveform analysis of acoustic emission technique on the identification of damage mode, location of damage position, quantitative assessment of damage degree and prediction of residual life of TBCs. The problems in current research are also outlined and the future development is proposed.
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2018, Vol. 32 
