Thermo-mechanical analysis and creep lifetime prediction of coated turbine vanes considering thermal barrier coating spallation characteristics

Quantitative analysis of the influence of thermal barrier coating spallation on the thermo-mechanical behaviors and creep lifetime of turbine vanes is crucial for their maintenance and reliability improvement. The temperature and stress distribution of vanes with preset coating spallation damage are investigated in this study, using the thermal-fluid-solid coupling method. Additionally, a further computational analysis is conducted to predict the hazardous regions and creep lifetime of the vanes. The results indicate that coating spallation leads to significant changes of the temperature and stress distribution at the spalled regions of vanes. The remaining coating on the unspalled regions continues to provide effective protection. Stress concentration primarily occurs at the upstream and downstream of the leading edge film holes, while high-stress regions are observed between adjacent rows of film holes, forming a serrated shape. The creep lifetime of the vanes decreases significantly at the region with coating spallation. When the same spallation area is considered, the coating spallation at the leading edge has a more serious influence on creep lifetime, which is more likely to cause the vanes failure. This study reveals the influence of coating spallation characteristics on the thermo-mechanical behaviors and creep lifetime of vanes, providing valuable insights for durability assessment of coated high-temperature components.