COMPOSITES SCIENCE AND TECHNOLOGY

Composites Science and Technology 66 (2006) 22492256 www.elsevier.com/locate/compscitech

Prediction of three-dimensional residual stresses in the multilayer coating-based systems with cylindrical geometry
X.C. Zhang
a

a,b,*

, B.S. Xu b, H.D. Wang b, Y. Jiang b, Y.X. Wu

State Key Laboratory of Metal Matrix Composites, Shanghai Jiaotong University, Shanghai 200030, PR China b National Key Laboratory for Remanufacturing, Beijing 100072, PR China Received 3 June 2005; received in revised form 25 November 2005; accepted 8 December 2005 Available online 24 January 2006

Abstract A numerical model has been developed to predict the thermally induced residual stresses in the multilayer coating-based systems with cylindrical geometry. During the cooling down, the axial forces in the longitudinal direction and the interfacial pressures in the radial direction were generated due to the mist strains resulting from the dierential thermal contraction and could be determined by the continuity conditions at the interfaces. The thermally induced residual stresses in the multilayer coating and the substrate can be predicted based on the solutions to the forces and pressures using layer-by-layer procedure. Specic analyses were made on the residual stresses within the multilayer ZrO2/NiCoCrAlY coatings with graded properties and compositions. Systematic studies were conducted on the eects of the compositional gradient, the thickness, the elastic modulus of the ceramic component of the coating on the residual stresses. Numerical modeling results showed that the residual stress distribution within a graded coating could be adjusted by controlling the compositional gradient. Changing in the coating thickness or in the ceramic component elastic modulus could alter the distribution and magnitude of residual stresses within the coating. 2005 Elsevier Ltd. All rights reserved.
Keywords: Numerical model; Residual stress; Multilayer coatings

1. Introduction Some analytical modes have been well developed so far to predict the thermal residual stress in the multilayer lms deposited on the substrates with planar geometry and some closed-form solutions have been obtained [1 5]. These analyses were mostly based on the classical beam theory and the strain compatibilities at the interfaces between adjacent layers. However, in practice, multilayer lms deposited on the substrates with cylindrical geometry have been often used as engineering components, and as specimens for performance evaluation [6].

Corresponding author. Tel.: +86 10 66718541; fax: +86 10 66717144. E-mail address: zhangxc@sjtu.edu.cn (X.C. Zhang).

As for the multilayer systems with cylindrical geometry, the concentric-circle model was often used to predict the residual stresses. For instance, the thermal or thermomechanical analysis of the ber-reinforced composites is a very active issue. Mikata et al. [7] investigated the elastic stress in a coated continuous ber composite subjected to thermo-mechanical loading using a four-concentric-cylinder model. By introducing a simple recursive algorithm considering only two concentric cylinders at one time, Sutcu [8] studied the residual stresses distributions in continuous ber composites with a number of coatings. Pindera et al. [911] proposed a micro-mechanical model based on an arbitrarily layered concentric cylinder conguration to calculate thermal stress elds in MMCs subjected to spatially uniform temperature changes. In their approach, the ber was modeled as a layered material with isotropic or orthotropic, elastic layers whereas the surrounding matrix

0266-3538/$ - see front matter 2005 Elsevier Ltd. All rights reserved. doi:10.1016/j.compscitech.2005.12.004

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and interfacial layers were treated as a strain-hardening, elasto-plastic, von Mises solid and the obtained global stiness matrix was solved iteratively at each temperature step. You [12] developed an analytical elasticplastic solution of thermally induced residual stresses for the composites reinforced with transversely isotropic, circumferentially orthotropic and radially orthotropic bers under thermomechanical loading based on a concentric cylinder model. When a penny-shaped crack existed in the center of the multiple concentric cylinders, Scott et al. [13] analyzed the stress elds and the stress concentrations. However, as for the coating-based system with cylindrical geometry, the studies were relatively few. Though some attempts have been devoted to predict the residual stresses within coating-based systems, they were limited to singlelayer and/or duplex coatings [6,14,15]. For instance, Tsui et al. [6] proposed a layer-by-layer approach to determine the stresses in progressively deposited coatings with cylindrical geometry. However, the individual coating layer had the identical material properties. Hsueh et al. [14] investigated the eect of thermally grown oxide on the residual stresses in the thermal barrier coatings (TBCs) using three-concentric-circle model. Subsequently, Limarga et al. [15] studied the eect of Al2O3 interlayer on residual stress elds in TBCs on the cylindrical substrates by extending the three-concentric-circle model to the fourconcentric-circle model. The purpose of this paper was to provide a numerical model to predict the thermally induced residual stresses in the multilayer coating-based systems with cylindrical geometry. This model was established based on Lame equations [16]. The solutions to the residual stresses in the individual coating layer and the substrate were obtained by considering the continuity conditions at the interfaces. In addition, specic analyses were made on the residual stresses within the multilayer ZrO2/NiCoCrAlY coatings with graded properties and compositions. The eects of thickness, material properties, and compositional gradient of the coating on the residual stresses were discussed. 2. Description of numerical model 2.1. Axial force and axial stress The origin of axial stresses, rz, developed in the substrate and the individual coating layer during the cooling down of the coating system from an elevated temperature is illustrated in Fig. 1, where n coating layers with individual thickness are bonded sequentially to the substrate. An elastic multilayer coating-based system at elevated temperature and under stress free condition is shown schematically in Fig. 1(a), where the inner and outer radii of the substrate are dened as r0 and r1, respectively, and the inner and outer radii of the ith coating layer are dened as ri and ri+1, respectively. With these denitions, the inner and outer radii of the last coating layer are characterized as

Fig. 1. Schematic depiction of the generation of the axial stressed in the individual coating layer and the substrate due to the opposite forces generated in the longitudinal direction during the cooling process.

rn and rn+1, respectively, and the total thickness of the coating layers can be written as tc = rn+1r1. Because of the temperature dierence, DT, the mist strains and the axial forces Fs and Fi will be generated in the substrate and ith coating layer, as shown in Fig. 1(b). However, in order to satisfy the equilibrium condition, the summation of axial forces in the whole system should be zero, that is n X F i F s 0. 1
i1

Once the axial forces Fi and Fs are determined, the axial stresses, rz, within the ith coating layer and the substrate can be expressed as rz i Fi 2 pr2 i1 r i Fs ; rz s 2 pr1 r2 0 1 6 i 6 n ; 2a 2b

where the subscripts i and s denote the ith coating layer and the substrate, respectively. 2.2. Radial stress and hoop stress According to Lame equations [16], if a cylinder is subjected to an uniformly distributed internal pressure, P, and a external pressure, P 0 , the radial stress, rr, and hoop stress, rh along the radial distance, r, can be obtained, rr rh P 0 b2 Pa2 P 0 P a2 b2 2 ; b2 a2 b a2 r 2 P 0 b2 Pa2 P 0 P a2 b2 2 ; b2 a2 b a2 r 2 3a 3b

where a and b are the inner and outer radii of a cylinder, respectively. It can be seen that at r = a ,rr = P and at r = b, rr = P 0 . Extending the Lame equations, the radial and hoop stresses in multilayer systems along the radial distance can be obtained. If the substrate is not subjected an internal pressure at r = r0 and is only subjected to a uniformly distributed external pressure, P1, the radial stress and hoop stress distributions in the substrate can be expressed as

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rr s

P 1 r2 P 1 r2 r2 1 2 0 21 2 ; 2 r 0 r 1 r 0 r P 1 r2 P 1 r2 r2 rh s 2 1 2 2 0 21 2 . r1 r0 r1 r0 r r2 1

4a 4b

The continuities of radial displacements at the interfaces should be maintained. At the interface between the substrate and the 1st coating layer (i.e., at r = r1), the continuity conditions can be expressed as rz s ms rh s rr s as D T Es rz 1 m1 rh 1 rr 1 a1 DT E1 rh s ms rz s rr s as D T Es rh 1 m1 rz 1 rr 1 a1 DT E1

Accordingly, if the ith coating layer is subjected to uniformly distributed internal and external pressures, Pi and Pi+1, as shown in Fig. 2, the radial stress and hoop stress distributions in it can be expressed as rr i rh i
2 2 P i1 r2 P i1 P i r2 i1 P i ri i r i 1 ; 2 2 2 r2 r 2 i1 r i i1 r i r 2 2 P i1 r2 P i1 P i r2 i1 P i ri i ri1 2 2 2 r2 r 2 i1 r i i1 r i r

r r 1 ;

8a

5a 1 6 i 6 n . 5b

r r 1 ;

8b

It can be seen that when r = ri+1, rr ijrri1 rr i1jrri1 P i1 . However, rh ijrri1

2 2 P i 1 r 2 i1 r i 2P i r i ; 2 2 ri1 ri 2 2 2P i2 r2 i2 P i1 ri1 ri2 . 2 2 ri2 ri1

where the subscript 1 denotes the 1st coating layer. Accordingly, at the interface between the ith coating layer and the (i + 1)th coating layer (i.e., at r = ri+1), the continuity conditions can be expressed as
rz i mi rh i rr i ai DT Ei rz i1 mi1 rh i1 rr i1 ai1 DT E i 1 rh i mi rz i rr i ai DT Ei rh i1 mi1 rz i1 rr i1 ai1 DT E i 1

6a 6b

rh i1jrri1

r ri1 ; 9a

2.3. Continuity conditions at the interfaces When the coating-based system is subjected to a uniform temperature dierence, both the strain in axial direction and that in hoop direction are composed of two parts, namely, elastic strain and the thermal strain, i.e., ez 1 rz mrh rr aDT ; E 1 eh rh mrz rr aDT ; E 7a 7b

r ri1 . 9b

2.4. Residual stress If the last coating layer is not subjected to an external pressure at r = rn+1, combining Eqs. (1),(2),(5),(8), and (9), the solutions to Fs, Fi, Pi can be obtained, which are related to the dimensions and the material properties of the substrate and the individual coating layer. Substituting the solutions to Fs, Fi and Pi into Eqs. (2), (4), and (5) the distributions of rz, rh and rr within the substrate and the individual coating layer can be determined. 2.5. For single-layer coating systems When a single layer coating is deposited on the substrate, the solutions to the axial forces, F, and the pressure at the coating/substrate interface, P1, can be expressed as pA BDT as ac  ; Fs  ABms ABmc 2 2 2 2 E s r r E c r r
s 0 c s

where ez is the axial strain and eh is the hoop strain, E is the elastic modulus, m is the Poissons ratio and a is the coecient of thermal expansion (CTE).

10a

pA BDT as ac  ; Fc  ABms ABmc 2 2 2 2 E s r r E r r

s 0 1 c s

10b

Fig. 2. Schematic depiction of the generation of the pressure generated at the interface between the adjacent layers in the radial direction during the cooling process.

D T as ac A BDT as ac  ; P1 B BEc r2 r2 ABms ABmc

c s
2 E s r 2 s r 0 2 E c r 2 c r s

10c

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where the parameters A and B are given by, A B

2 2 r2 r2 mc mc s r0 c rs ; 2 2 r2 E s r 2 r E r E Ec c c s 0 s s

11a 11b

2r 2 2r 2 s mc s ms ; 2 2 2 Ec rc rs Es rs r2 0

where the subscript c denotes the coating and rs, rc are the outer radii of the substrate and the coating, respectively. In fact, the solutions can also be seen in Tsui et al.s model [6]. When the outer radius of the substrate goes to innite, i.e., rs ! 1, rc ! rs and r0 0, the residual stress distributions approach that for planar geometry with no bending, but with free movement in the in-plane directions. In such case, substituting Eq. (10) into Eqs. (2) and (5), the stresses in the coating can be rewritten as, rz c rhc rrc 0. Ec as ac DT ; 1 mc 12a 12b

The expression of axial stress is in agreement with that of the normal stress in the coating with planar geometry and has been concluded elsewhere [17,18]. 2.6. Numerical model It should be noted that the number of continuity conditions at interfaces to be satised increases as the number of coating layers increases. Hence, for multilayer coating system, obtaining a closed-form solution is highly complicated and the analysis is only left to the computer. In this paper, a numerical model is set up based on the analytical model proposed above. The ow chart showing the algorithm for the numerical model can be seen in Fig. 3. Once the dimensions, material properties of the substrate and the individual coating layer are dened, the implementation of the model is fairly straightforward. The main advantage of this model is that the solutions to residual stresses are independent of the number of coating layers. In order to illustrate the use of the present numerical model, typically duplex-layer and functionally graded ZrO2/NiCoCrAlY TBCs on the Ni alloy substrate are studied, because these coatings are often subjected the thermal cycling. 3. Results and discussions Generally, the typical TBC system includes a NiCoCrAlY metallic bondcoat and a ZrO2 ceramic topcoat on a Nialloy substrate. However, the major limitation to expand the application range of TBCs lies in their premature failures and, as a result, their poor reliability. A large number of experimental researches indicated that the failures of typical TBCs are related to the large residual stress discontinuity at the bondcoat/topcoat interface [19]. In order to reduce this stress discontinuity, the concept of gradient material has been introduced into TBCs [20] and some advanced multilayer TBCs with graded proper-

Fig. 3. The ow chart showing the logic of the numerical model to calculate the residual stresses in multilayer coating-based system with cylindrical geometry.

ties and compositions have been fabricated [21,22]. For compositionally graded TBC on a substrate with planar geometry, the normal residual stress prediction models have been proposed by Huseh et al. [23] and Zhang et al. [5]. In their models, the graded coating was considered as a single layer and can be characterized by a continuously changing physical property due to a continuous change in composition, in morphology, or in microstructure from metallic material to ceramic material with increasing the coating thickness. As to the functionally graded TBC, the composition varies in the thickness direction from 100% metal layer for the topcoat to 100% ceramic layer for the topcoat [22], and the compositional change from layer to layer is stepwise. For the planar geometry, the stress elds in functionally graded TBC were predicted by Kor et al. [22] using nite element method. In their model, the total number of the coating layers was limited to ve. However, up to now, there are few researches on the prediction of the residual stresses within the functionally graded TBC on a cylindrical substrate. In this paper, the residual stresses within the typical duplex and the functionally graded TBCs were predicted.

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In the case of elastic deformation, the material properties of ith layer of the coating can be determined by the widely used Vegards rule of mixtures [24,25],  k i1 E i E m E c E m ; 13a n1  k i1 ai am ac am ; 13b n1  k i1 mi mm mc mm ; 13c n1 where the subscripts m refers to the metallic material, i.e., NiCoCrAlY, and c denotes the ceramic material, i.e., ZrO2, k is the gradient exponent that controls the shape of non-linear or linear compositional gradient. The material properties required for the analyses are listed in Table 1 [14,22,26]. It should be noted that the material properties at room temperature are used. In all cases, the coating systems are assumed to be stress free at a reference temperature, i.e. 800 K, which is assumed to be equal to the deposition temperature [22]. The room temperature is assumed to be 298 K, hence, the temperature dierence is 402 K. For all calculations, the inner and outer radii of the substrate are kept of 5 and 8 mm, respectively. For each graded TBC, it is assumed that all layers have the identical thickness and the total number of them n = 50. 3.1. Results for duplex TBC For calculated duplex TBC system, the thicknesses of the bondcoat and the topcoat are 0.2 and 0.4 mm, respectively, and the distributions of the radial stress, axial stress and hoop stress along the radial distance r are shown in Fig. 4. It can be seen that the axial stress and hoop stress in the substrate are tensile, and they are compressive in the bondcoat and topcoat. This phenomenon is attributed to the CTEs of the bondcoat and the topcoat are lower than the CTE of the substrate. Conversely, if the bondcoat and topcoat have larger CTEs, the compressive stress will be developed in the substrate. It also can be seen that the distribution of the axial stress is similar to that of the hoop stress. The maximal hoop stress is located at the interface between the bondcoat and the topcoat. However, it should be noted that there is a larger stress discontinuity at the bondcoat/topcoat interface, which may lead to the premature failure of the coating. The radial stress is always tensile and increases from zero until a maximum value about 9.42 MPa at the bondcoat/substrate interface and then decreases to zero.
Table 1 Material properties used in the calculations [14,22,26] Material IN718 substrate NiCoCrAlY ZrO2 E (GPa) 200 225 80 m 0.3 0.3 0.25 a (106/K) 14.4 14 10

Fig. 4. Residual stress distributions along the radial distance in the duplex TBC system.

3.2. Eect of compositional gradient on the stresses in graded TBC The eect of compositional gradient on the residual stresses in the functionally graded TBC is shown in Fig. 5, where the compositional gradient is characterized by the gradient exponent k in Eq. (13) and the total thickness of coating layers is kept of 0.6 mm. It is clear that the thermal residual stress in the graded TBC is strongly inuenced by the compositional gradient. When k is less than 1.0, e.g., k = 0.5, the axial and hoop stresses in the metallic-rich region near the substrate/coating interface increase sharply, while when k is larger than 1, these stresses in the ceramicrich region near the coating surface increases sharply. This is because when k < 1.0, the volume fraction of the ceramic material increases quickly near the coating/substrate interface. Conversely, when k > 1.0, the volume fraction of the ceramic material increases quickly near the coating surface [5]. If the linear prole is assumed (i.e. k = 1.0), they change slowly along the radial direction. Hence, the magnitude and distribution of thermal stresses within a coating can be adjusted by controlling the compositional gradient. In addition, the axial and hoop stresses in the substrate near the coating/substrate interface are always tensile and decrease with increasing the magnitude of k. Whether k is small or large, It is interesting to nd that the maximal axial stress and hoop stress are not located at the coating surface or interface, but in the coating, and the their values are larger than those for the duplex TBC. With increasing the magnitude of k, the maximum values increase. At the graded coating surface, the magnitudes of the axial stress and hoop stress are almost equal to them at the duplex TBC surface. However, it should be noted that the axial and hoop stress discontinuities at the bondcoat/topcoat interface are eliminated when the typical TBC is replaced by the graded TBC. For all graded TBCs, the maximal axial stress is still located at the coating/substrate interface and its value decreases with increasing the exponent k. When k is relative

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large, the value of the maximal axial stress will be lower than that for typical TBC system.
(a)

3.3. Eect of coating thickness on the stresses in graded TBC The residual stresses in a functionally graded TBC are strongly dependent on the coating thickness, as shown in Fig. 6, where the compositional prole of the coating is linear. It can be seen that with increasing the coating thickness, the axial and hoop stresses at the coating surface and the coating/substrate interface increase. Whether the coating is thin or thick, the maximal axial and hoop stresses are always located in the coating. In addition, the axial and hoop stresses in the substrate near the coating/substrate interface are always tensile and increase with increasing the coating thickness. The radial stresses in the substrate and the coating are always tensile for all systems and the maximal stress is still located at the coating/substrate interface. With decreasing the coating thickness, the value of maximal stress decreases obviously. From the above discussions, it can be concluded that changing the graded coating thickness can change the magnitude of the residual stresses in the coating system, but cannot alter the distribution of the residual stresses. In order to minimize the stresses at the coating/substrate interface and at the coating surface, the coating should be as thin as possible. 3.4. Eect of elastic modulus of ZrO2 ceramic component on residual stresses The values of elastic modulus ranging from 20 to 100 GPa are typical for ZrO2 ceramic due to dierent deposition conditions and after some sintering eects during the high temperature exposure [27]. In order to investigate the inuence of the material properties of the ceramic component on the residual stresses within a functionally graded TBC, ZrO2 ceramic components with dierent elastic moduli are used to model. The relevant result is presented in Fig. 7, where the coating thickness is 0.6 mm. It can been seen that within increasing the elastic modulus of the ZrO2 ceramic component, the magnitudes of the axial stress and hoop stress in the substrate and the coating increase. At the same time, the elastic modulus of the ZrO2 ceramic component has an obviously inuence on the coating surface. Interestingly, when the elastic modulus of ceramic component is low enough (e.g., 20 GPa), the maximal axial and hoop stresses are located near the centerline of coating and become less compressive towards the coating surface. When the compositional prole is linear, the eect of elastic modulus of ceramic component on the residual stress from the coating/substrate interface to the centerline is invisible, while this eect is pronounced from the centerline to the coating surface [5]. Hence, it can be concluded that change in the material properties of the cera-

(b)

(c)

Fig. 5. Eect of the compositional gradient which is characterized by the gradient exponent, k, on the residual stress distributions along the radial distance in the functionally graded TBC system: (a) axial stress; (b) hoop stress and (c) radial stress.

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(a)

(a)

(b) (b)

(c) (c)

Fig. 6. Eect of the coating thickness on the residual stress distributions along the radial distance in the functionally graded TBC system: (a) axial stress; (b) hoop stress and (c) radial stress.

Fig. 7. Eect of the elastic modulus of the ZrO2 ceramic component of coating on the residual stress distributions along the radial distance in the functionally graded TBC system: (a) axial stress; (b) hoop stress and (c) radial stress.

mic component and/or the metallic component in a graded TBC can alter the distribution and magnitude of residual stresses within the coating. In addition, the max-

imal radial stress at the coating/substrate interface increases obviously as the elastic modulus of the ceramic component increases.

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X.C. Zhang et al. / Composites Science and Technology 66 (2006) 22492256 [5] Zhang XC, Xu BS, Wang HD, Jiang Y, Wu YX. Modeling of thermal residual stresses in multilayer coatings with graded properties and compositions. Thin Solid Films [in press]. [6] Tsui YC, Clyne TW. An analytical model for predicting residual stresses in progressively deposited coatings. Part 2: Cylindrical geometry. Thin Solid Films 1997;306(1):3451. [7] Mikata Y, Taya M. Stress eld in a coated continuous ber composite subjected to thermo-mechanical loading. J Compos Mater 1985;19(6): 55478. [8] Sutcu M. A recursive concentric cylinder model for composites containing coated bers. Int J Solids Struct 1992;29(2):197213. [9] Pindera MJ, Freed AD, Arnold SM. Eects of ber and interfacial layer morphologies on the thermoplastic response of metal matrix composites. Int J Solids Struct 1993;30(9):121338. [10] Pindera MJ, Arnold SM, Williams TO. Thermoplastic response of metal matrix composites with homogenized and functionally graded interfaces. Compos Eng 1994;4(1):12945. [11] Williams TO, Pindera MJ. TMF modeling of advanced metal matrix composites in the presence of microstructural details. Mater Sci Eng 1995;200A(12):15672. [12] You LH. Eect of elasticplastic matrix on thermo-mechanical response of continuous anisotropic ber-reinforced composites. Compos Sci Technol 2002;62(16):220918. [13] Case Scott W, Reifsnider Kenneth L. Micromechanical analysis of ber fracture in unidirectional composite materials. Int J Solids Struct 1996;33(26):3795812. [14] Hsueh CH, Fuller Jr ER. Analytical modeling of oxide thickness eects on residual stresses in thermal barrier coatings. Scripta Mater 2000;42(8):7817. [15] Limarga AM, Widjaja S, Yip TH, Teh LK. Modeling of the eect of Al2O3 interlayer on residual stress due to oxide scale in thermal barrier coatings. Surf Coat Technol 2002;153(1):1624. [16] Gere JM, Timoshenko SP. Mechanics of materials. London: Chapman & Hall Inc.; 1991. [17] Lee JD, Ra HY, Hong KT, Hur SK. Analysis of deposition phenomena and residual stress in plasma spray coatings. Surf Coat Technol 1992;56(1):2737. [18] Shaw LL. Thermal residual stresses in plates and coatings composed of multi-layered and functionally graded materials. Compos Part B 1998;29(3):199210. [19] Pindera MJ, Aboudi J, Arnold SM. Analysis of spallation mechanism in thermal barrier coatings with graded bond coats using the higherorder theory for fgms. Eng Fract Mech 2002;69(1416):1587606. [20] Kim JH, Kim MC, Park CG. Evaluation of functionally graded thermal barrier coatings fabricated by detonation gun spray technique. Surf Coat Technol 2003;168(23):27580. [21] Kokini K, dejonge J, Rangaraj S, Beardsley B. Thermal shock of functionally graded thermal barrier coatings with similar thermal resistance. Surf Coat Technol 2002;154(23):22331. [22] Khor KA, Gu YW. Eects of residual stress on the performance of plasma sprayed functionally graded ZrO2/NiCoCrAlY coatings. Mater Sci Eng 2000;A277(12):6476. [23] Hsueh CH, Lee S. Modeling of elastic thermal stresses in two materials joined by a graded layer. Compos Part B 2003;34(8): 74752. [24] Drake JT, Williamson RL, Rabin BH. Finite element analysis of thermal residual stresses at graded ceramic-metal interfaces. Part I. Model description and geometrical eects. J Appl Phys 1993;74(2): 131020. [25] Adachi S. GaAs, AlAs, and AlxGa1xAs material parameters for use in research and device applications. J Appl Phys 1985;58(3):R1R29. [26] Widjaja S, Limarga AM, Yip TH. Modeling of residual stresses in a plasma sprayed zirconia/alumina functionally graded-thermal barrier coating. Thin Solid Films 2003;434(12):21627. [27] Teixeira V. Numerical analysis of the inuence of coating porosity and substrate elastic properties on the residual stresses in high temperature graded coatings. Surf Coat Technol 2001;146147:7984.

4. Conclusions A numerical model has been developed to predict the thermally induced residual stresses in the multilayer coating on a substrate with cylindrical geometry. The axial forces in the longitudinal direction and the interfacial pressures in the radial direction, which were generated due to the dierential thermal contraction between the adjacent layers, could be determined by the continuity conditions at the interfaces in the longitudinal and hoop directions using layer-by-layer procedure. Despite the model set up in the present paper was based on the elastic analysis, it could be easily adapted to illustrate the general trends in the residual stress in a multilayer coating on a cylindrical substrate. Specic analyses were made on the residual stress in the typical duplex and functionally graded ZrO2/NiCrAlY TBCs. Results showed that, the distribution of the axial stress was similar to that of the hoop stress in the coating. For the graded TBC system, the maximal hoop and axial stresses were located in the coating, not at the surface or interface, and the maximal radial stress was located at the substrate/coating interface. The magnitude and distribution of thermal stresses within a graded coating could be adjusted by controlling the compositional gradient which was characterized by a gradient exponent. In order to minimize the stresses at the coating/substrate interface and at the coating surface, the coating should be as thin as possible. Changing in the material properties of the ceramic component and/or the metallic component could alter the distribution and magnitude of residual stresses within the graded coating. Acknowledgements The authors thank Drs. S.T. Tu and B. Wu for helpful discussions and reviewing the manuscript. Research sponsored by China Natural Science Foundation (50235030), the National Development Scheme of Key Fundamental Research (Nation 973 Project) of China (G1999065009). Two of the authors (X.C. Zhang and Y.X. Wu) are also grateful to the support by the Planed project of Shanghai Science & Technology Commission (036105001) and the international Science & Technology Collaboration Project (2004DFA02400). References
[1] Tsui YC, Clyne TW. An analytical model for predicting residual stresses in progressively deposited coatings. Part 1: Planar geometry. Thin Solid Films 1997;306(1):2333. [2] Hsueh CH. Thermal stresses in elastic multilayer systems. Thin Solid Films 2002;418(2):1828. [3] Teixeira V. Mechanical integrity in PVD coatings due to the presence of residual stresses. Thin Solid Films 2001;392(2):27681. [4] Zhang XC, Xu BS, Wang HD, Wu YX. An analytical model for predicting thermal residual stresses in multilayer coating systems. Thin Solid Films 2005;488(12):17482.