The knowledge of the rupture mechanism of multilayer systems is necessary for improving the bonding of materials, particularly for the ceramic-to-metal junctions, and especially in the case of the ceramic coatings on metallic substrates. For this purpose, coupling experimental measurements of macroscopic interfacial adhesions with numerical tools of fracture mechanics allow understanding how the stress distribution and the cracking mechanisms are influenced by the local environment. This brings an explanation to the cracks initiation and propagation and to the role of local characteristics of the interfacial zone. The present work illustrates this, in the case of alumina coatings strongly bonded to C35 steel substrates previously pre-oxidized in CO2. The experimental tool is based on the “silver print test”. It consists in covering the central part of the samples with a thin layer of silver paint before coating in order to create a defect zone. Concerning the numerical part, the finite element method is used as a powerful tool to describe the mechanical phenomena at the local scale influencing the crack propagation. The obtained numerical results show a good agreement with the experimental observations and they allow a local description of the phenomena influencing the cracking mechanism. Moreover, they lead to a concrete proposition for improving the coatings adherence.
ChenRYYeunWYD.Review of the high-temperature oxidation of iron and carbon steels in air or oxygen.Oxid Met2003;
59: 433–468.
2.
ChangYNWeiFI.High temperature oxidation of low alloy steels.J Mater Sci1989;
24: 14–22.
3.
ArivazhaganNNarayananSSinghS, et al.High temperature corrosion studies on friction welded low alloy steel and stainless steel in air and molten salt environment at 650°C.Mater Des2012;
34: 459–468.
4.
EnnisPJZielinska-LipiecAWachterO, et al.Microstructural stability and creep rupture strength of the martensitic steel P92 for advanced power plant.Acta Mater1997;
45: 4901–4907.
5.
AbeF.Precipitate design for creep strengthening of 9% Cr tempered martensitic steel for ultra-supercritical power plants.Sci Technol Adv Mater2008;
9: 013002.
6.
GallonMJ.Managing structural corrosion in chemical plants.New Steel Constr1993;
1: 14–15.
7.
BernardieRValetteSAbsiJ, et al.Mechanical characterization of alumina coatings on C35 steel.Surf Coat Technol2015;
276: 677–685.
8.
ValetteSTrolliardGDenoirjeanA, et al.Iron/wüstite/magnetite/alumina relationships in plasma coated steel: a TEM study.Solid State Ionics2007;
178: 429–437.
9.
ValetteSDenoirjeanALefortP.Plasma sprayed steel: adhesion of an alumina film via a wüstite interlayer.Surf Coat Technol2008;
202: 2603–2611.
10.
KishiAKurodaSInoueT, et al.Tensile test specimens with a circumferential precrack for evaluation of interfacial toughness of thermal-sprayed coatings.J Therm Spray Technol2008;
17: 228–233.
11.
LesageJChicotD.Role of residual stresses on interface toughness of thermally sprayed coatings.Thin Solid Films2002;
415: 143–150.
12.
GuoSQMummDRKarlssonAM, et al.Measurement of interfacial shear mechanical properties in thermal barrier coating systems by a barb pullout method.Scripta Mater2005;
53: 1043–1048.
13.
SexsmithMTroczynskiT.Peel adhesion test for thermal spray coatings.J Therm Spray Technol1994;
3: 404–411.
14.
LinCKBerndtCC.Measurement and analysis of adhesion strength for thermally sprayed coatings.J Therm Spray Technol1994;
3: 75–104.
CaiJGuanQLvP, et al.Adhesion strength of thermal barrier coatings with thermal-sprayed bondcoat treated by compound method of high-current pulsed electron beam and grit blasting.J Therm Spray Technol2015;
24: 798–806.
17.
QianGNakamuraTBerndtCC, et al.Tensile toughness test and high temperature fracture analysis of thermal barrier coatings.Acta Mater1997;
45: 1767–1784.
18.
WatanabeMKurodaSYokoyamaK, et al.Modified tensile adhesion test for evaluation of interfacial toughness of HVOF sprayed coatings.Surf Coat Technol2008;
202: 1746–1752.
19.
MoësNBelytschkoT.Extended finite element method for cohesive crack growth.Eng Fract Mech2002;
69: 813–833.
20.
GuoFGuoLHuangK, et al.An interaction energy integral method for T-stress evaluation in nonhomogeneous materials under thermal loading.Mech Mater2015;
83: 30–39.
21.
SadowskiTGolewskiP.Detection and numerical analysis of the most efforted places in turbine blades under real working conditions.Compos Mater Sci2012;
64: 285–288.
22.
BhattacharyaSSinghIVMishraBK.Fatigue life simulation of functionally graded materials under cyclic thermal load using XFEM.Int J Mech Sci2014;
82: 41–59.
23.
BhattacharyaSSinghIVMishraBK.Fatigue-life estimation of functionally graded materials using XFEM.Eng Comput2013;
29: 427–448.
24.
GalESudayEWaismanH.Homogenization of materials having inclusions surrounded by layers modeled by the extended finite element method.Int J Multiscale Comput Eng2013;
11: 239–252.
25.
LuPXiaoXChouYK.Interface delamination study of diamond-coated carbide tools considering coating fractures.Surf Coat Technol2014;
260: 239–245.
26.
BenvenutiE.XFEM with equivalent eigenstrain for matrix–inclusion interfaces.Comput Mech2014;
53: 893–908.
27.
SunYLiuM.Analysis of the crack penetration/deflection at the interfaces in the intelligent coating system utilizing virtual crack closure technique.Eng Fract Mech2015;
133: 152–162.
28.
LeeC-CSuY-FWuC-S, et al.Investigation of interconnect design on interfacial cracking energy of Al/TiN barriers under a flexural load.Thin Solid Films2013;
544: 530–536.
29.
DonohueEMPhilipsNRBegleyMR, et al.Thermal barrier coating toughness: Measurement and identification of a bridging mechanism enabled by segmented microstructure.Mater Sci Eng A2013;
564: 324–330.
30.
Ranjbar-farMAbsiJMariauxG, et al.Crack propagation modeling on the interfaces of thermal barrier coating system with different thickness of the oxide layer and different interface morphologies.Mater Des2011;
32: 4961–4969.
31.
Ranjbar-FarMAbsiJMariauxG.Finite element modeling of the different failure mechanisms of a plasma sprayed thermal barrier coatings system.J Therm Spray Technol2012;
21: 1234–1244.
32.
ValetteSDenoirjeanATétardD, et al.C40E steel oxidation under CO2: kinetics and reactional mechanism.J Alloy Compd2006;
413: 222–231.
33.
ShihCFAsaroRJ.Elastic-plastic analysis of cracks on bimaterial interfaces: part I—small scale yielding. J Appl Mech1988;
55: 299–316.
34.
BarnettDMAsaroRJ.The fracture mechanics of slit-like cracks in anisotropic elastic media.J Mech Phys Solids1972;
20: 353–366.
35.
GaoHAbbudiMBarnettDM.Interfacial crack-tip field in anisotropic elastic solids.J Mech Phys Solids1992;
40: 393–416.
36.
Ranjbar-FarMAbsiJMariauxG, et al.Simulation of the effect of material properties and interface roughness on the stress distribution in thermal barrier coatings using finite element method.Mater Des2010;
31: 772–781.
37.
Ranjbar-FarMAbsiJMariauxG, et al.Effect of residual stresses and prediction of possible failure mechanisms on thermal barrier coating system by finite element method.J Therm Spray Technol2010;
19: 1054–1061.
38.
RiceJ Paris PMerkleJ. Some further results of j-integral analysis and estimates. In: Kaufman J, Swedlow J, Corten H, et al. (eds) Progress in flaw growth and fracture toughness testing. West Conshohocken, PA: ASTM International, 1973, pp. 231–245.
