Physics Based Prognostic Health Management for Thermal Barrier Coating System



Amar Kumar Bhavaye Saxena Alka Srivastava Alok Goel


Reliable prognostic of thermal barrier coating systems (TBCs) as applied to hot section engine components is a challenging task. Physics based approach is made here involving both experimental physical damage signature analysis and thermal cycle simulations. Thermally grown oxides (TGO) and the developing cracks in TBCs increase with thermal exposures. An exponential relationship is observed between the two parameters. Significant variations in size and characteristics of the damage signatures are observed depending on the four typical cycle profiles considered. In this paper, fourth order Runge-Kutta method is used for the numerical analysis of the differential equation for TGO growth analysis. Damage tolerance approach considering fracture mechanics based stress intensity factor is used to determine the crack tolerance level and remaining useful life. Our earlier fracture mechanical model for composite TBCs is modified assuming the crack to nucleate and grow within the TBC and not inside TGO. An overview of the PHM solution is presented.

How to Cite

Kumar, A. ., Saxena , B., Srivastava, A., & Goel, A. . (2011). Physics Based Prognostic Health Management for Thermal Barrier Coating System. Annual Conference of the PHM Society, 3(1).
Abstract 10 | PDF Downloads 2



remaining life, Thermal barrier coating, oxide growth, crack size, damage tolerance, thermal cycle similation

Chin, H. H., Turbine engine hot section prognostics, Turbine %20Engine%20Hot%20Section%20Prognostics .pdf

Wood, M. I.,(2000), Gas turbine hot section components: the challenge of residual life assessment, Proceedings of Instituion of Mechanical Engrs., 214 part A, pp. 193-201.

Christodoulou, L. & Larsen, J. M.,(2005), Material Damage Prognosis: A Revolution in Asset Management, in Material damage Prognosis (ed. J M Larsen, TMS, pp. 3-10.

Intellistart+, Altair avionics/Pratt & Whitney; http://www. altairavionics .com/

SignalProTM ,Impact http://impact Aerospace/ Aerospace.html

NormNetPHM, Frontier Technology Inc., http://www.fti/ products/NormNet-prod/ NormNet.html

Shillington, E.A.G. & Clarke, D.R.,(1999), Spalling failure of a thermal barrier coating associated with aluminium in the bond coat, Acta Materialia., vol. 47, 4, pp.1297- 1305.

Evans, A. G., Mumm, D. R., Hutchinson, J. W., Meier, G. H. & Pettit, F. S.,(2001), Mechanisms controlling the durability of thermal barrier coatings, Progress in Materials science, vol.46, pp. 505-533.

Kumar, A. N., Nayak, A., Patnaik, A. R., Wu, X. & Patnaik, P.C., (2007), Instability analysis for thermal barrier coatings by fracture mechanical modelings, Proceedings of GT2007, ASME Turbo Expo 2007: Power for Land, Sea and Air, GT 2007 – 27489, Montreal, QC.

Karlsson, A. M, Xu, T. & Evans, A G., (2002), The effect of thermal barrier coating on the displacement instability in thermal barrier system, Acta Materialia, vol.50, pp. 1211-1218.

Chen, W. R., Wu, X., Marple, B. R. & Patnaik, P.C.,(2005), Oxidation and crack nucleation/growth in an air- plasma-sprayed thermal barrier coating with NiCrAlY bond-coat, Surface and Coating and Technology, vol. 197, pp. 109-115.

Clarke, D R., Levi, C. G. &Evans, A. G.,(2006), Enhanced zirconia thermal barrier coating systems, Journal of Power and Energy, Proc. I. MechE, vol. 220, pp.85- 92.

He, M.Y., Hutchinson, J. W. 7 Evans, A. G.,(2003),Simulation of stresses and delamination in a plasma- sprayed thermal barrier system upon thermal cycling, Materials science and Engineering, vol. A345, pp. 172-178.

LeMieux, D. H., (2003), Online thermal barrier coating monitoring for real time failure protection and life maximization, Report US Department of Energy, DE- FC26 -01NT41232.

Kumar, A., Srivastava, A., Goel, N., & Nayak, A., (2010), Model based approach and algorithm for fault diagnosis and prognosis of coated gas turbine blades, Proceeding of IEEE/ASME International conference on Advanced Intelligent Mechatronics, Montreal, QC.

Kumar, A., Nayak, A., Srivastava, A., & Goel, N. (2009), Experimental validation of statistical algorithm for diagnosis of damage fault, Proceedings of IEEE Canadian conference on electrical and computer engineering, St. John’s.

Chen, W.R., Wu, X., Marple, B.R. and Patnaik, P.C.,(2006), The growth and influence of thermally grown oxide in a thermal barrier coating, Surface and Coating Technology, vol. 201,pp.1074-1079.

Carlsson, K.,(2007), A Study of failure development in thick thermal barrier coating. Master thesis in Mechanical Engineering, Linkopings University Tekniska Hogskolan, Sweden.
Anderson, T. L., (1995), Fracture Mechanics: Fundamentals and Applications, Boca Raton, CRC Press, USA.

Mao, W. G., Zhou, Y. C., Yang, L., & Yu, X. H. (2006), Modeling of residual stresses variation with thermal cycling in thermal barrier coatings, Mechanics of Materials, vol. 38, pp. 1118-1127.

Sidhu, B.S. & Prakash, S. (2005), High temperature oxidation behavior of NiCrAlY bond coats and stellite -6 plasma –sprayed coatings”, Oxidation of Metals, vol. 63, 314, pp. 241-259.

Nusier, S. Q., Newas, G. M & Chaudhury, Z. A. (2000), Experimental and analytical evaluation of damage processes in thermal barrier coatings, International Journal of Solids and Structures, vol. 37, 18, pp. 2495-2506.
Technical Papers

Most read articles by the same author(s)