Session: 02-03 Thermal and Environmental Barrier Coatings

Paper Number: 83469

83469 - ICME Computational Framework for Ceramic APS Coatings 

This work shows an enhanced Integrated Computational Material Engineering (ICME) and lifing predictive method for multi-material coating of Air Plasma Spray Physical Vapor Deposition (APS-PVD) Ceramic Coating Process. ICME prediction included APS-PVD process, In-service Burner-Rig and furnace tests of thermal loading conditions, and the effect of high temperature thermal/environmental Barrier Coatings (TBC/EBC) over metallic substrate of dog bone specimens to demonstrate durability and damage tolerance (D&DT).

Method: A Multiphysics-based ICME methodology, and virtual design of experiment (DOE) software is developed to design multifunctional layered materials including high temperature coatings for use in engine/aircraft high temperature exhaust regions. The ICME innovation centers around: 1) Thermo-Physics Modeling (plasma, vapor, liquid, solid) to predict the a) material’s thermal profile, voids, densities, and thermal conductivities, and mass loss; 2) Multiscale Material Modeling of Top Layer, Bond Coating, and Substrate to predict material performance: a) strength, stiffness, residual stresses and strains vs. temperature considering the effect of defects, and b) rumpling and surface waviness, and Thermal Growth Oxidation (TGO); 3) Structural Analysis and D&DT to predict coating and substrate failure evolution (i.e., spallation, delamination, oxidation, etc.) during thermo-mechanical in-service loading; and 4) Single or Multi- Objective Optimizations to maximize durability by minimizing residual stress/strains to enhance coating life. Verification was performed using test data on TBC/Waspaloy systems under thermal mechanical loading.

Findings: Tests and predictions are in close agreement. Both test and ICME prediction show the as-built dog bone specimen exhibiting bending during APS-PVD, and delamination during BurnerRig and Furnace testing of specimens respectively. Finally, the life and maintenance of optimized coupons and tactical fighter aircraft seals and flaps will be predicted and optimized.

Presenting Author: Dr. Frank Abdi AlphaSTAR Technology Solutions

Presenting Author Biography: Frank Abdi is the founder of AlphaSTAR Technology Solutions, renowned aerospace scientist, and distinguished author. For over forty years he has contributed leadership to solving advanced material challenges including the derivation and modification of theoretical equations, aero-elastic tailoring, optimization, advanced material design, fracture mechanics, and structural mechanics. At AlphaSTAR he has assembled a team of scientists and engineers that represent a large repository of advanced material methods &amp; solutions.<br/><br/>Prior to AlphaSTAR, Dr. Abdi led Rockwell International&#39;s Advanced Program&#39;s Controlled Configured Vehicle Research organization. Key projects included the design and simulation of: NASP (X30), B1-B bird strike, Advanced Launch System, Boosted Penetrator, Swedish Fighter, Special Operation Aircraft, and the space shuttle redesign.<br/><br/>Dr. Abdi earned his B.S. and M.S. in Mechanical Engineering from University of Michigan and his Ph.D. in Mechanical Engineering from University of Southern California. He has published numerous journal papers and books in optimization, nanotechnology, materials science and computational structural analysis. Dr. Abdi continues to embrace academic partners and remains active in the American Society of Mechanical Engineers, AIAA (member of Optimization Committee and Adaptive Structure Committee, NASA Ames, Committee in Aircraft Conceptual Design, and SAE member of RMS Committee. Dr. Abdi is currently serving as adjunct professor at University of California Los Angeles, Department of Material Science and at Imperial College of London, Department of Mechanical Engineering. He is the recipient of NASA achievement award for his contribution to the Shuttle Columbia Accident investigation in 2003.

Authors:

Dr. Frank Abdi AlphaSTAR Technology Solutions
Vasyl Harik AlphaSTAR Technology Solutions
Reza Yaghmaie AlphaSTAR Technology Solutions
Harsh Baid AlphaSTAR Technology Solutions
Daniel Balint Imperial College London
Gregory Morscher University of Akron
Larry Zawada Arctos Technology Solutions
George Jefferson Airforce Research Laboratory, AFRL/RXCC
Surekha Achanta AlphaSTAR Technology Solutions