Thermal fracture of functionally graded thermal barrier coatings with pre-existing edge cracks and multiple internal cracks imitating a curved interface

Abstract

This work is devoted to the problem of thermal fracture of a functionally graded coating on a homogeneous substrate (FGC/H) with an emphasis on the analysis of a special system of cracks that simulates a curved interface. The FGC/H structure contains the pre-existing crack system in the FGC, both edge cracks (which are often seen in FGC/H structures) and internal cracks. The stress intensity factors are calculated. (Generally, both Mode I and Mode II are nonzero.) Then, using the appropriate fracture criterion for mixed-mode fracture conditions, the crack propagation direction (so-called fracture angles) and critical loads, when this propagation is initiated, are determined. The application of fracture criteria requires knowledge of the fracture toughness near the crack tips. Thus, it is assumed that the fracture toughness of an FGC, as well as other material properties, continuously varies through the thickness of the coating. For multiple cracks, it is also important to know the weakest crack that starts to propagate first, and the initial direction of this growth. Therefore, the main attention is paid to the evaluation of the fracture angles for the cracks for different parameters of the FGC/H structure. Both cases of a homogeneous semi-infinite medium with a system of cracks imitating a curved interface and FGC/H structures with identical crack systems are studied.