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Effect of CMAS-Filled Pore Morphology on Thermomechanical Behavior of Thermal Barrier Coatings
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DOI：10.1007/s11666-026-02305-3.png)
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Abstract
En 中文
Corrosion failure induced by molten CaO-MgO-Al2O3-SiO2 (CMAS) infiltration critically limits thermal barrier coatings (TBCs) durability. This study develops a finite element model incorporating CMAS penetration into the ceramic layer to investigate how the morphology and size of CMAS-filled pores affect thermomechanical behavior. The results show that larger aspect ratios promote smoother heat conduction and reduce peak heat flux from 3 to 2.4 W/mm2, while stress concentration at pore tips intensifies with Smax reaching 155 MPa. Under smaller aspect ratios, the shear stress exhibits significant fluctuations, with peak values approaching 120 MPa. Enlarged circular pores induce localized heat flux concentration, whereas elliptical pores cause stronger Smax fluctuations, increasing by 35.4%. For the sinusoidal CMAS–ceramic interface, circular pores yield higher interfacial stress and greater crack susceptibility than elliptical ones. This work provides significant theoretical insights into the influence of CMAS-filled pore morphology on the thermomechanical performance of TBCs. This study presents a finite element analysis of how CMAS-filled pore morphology and size affect thermomechanical behavior in APS YSZ thermal barrier coatings. By comparing circular and elliptical filled pores with different characteristic dimensions and aspect ratios, the work clarifies the coupled effects of CMAS filling, pore geometry, and interfacial morphology on heat-flux redistribution, temperature evolution, and local stress concentration. The results identify elongated elliptical pores and sharp pore tips as damage-sensitive regions, providing mechanistic insight into CMAS-induced degradation and guidance for interpreting pore-controlled failure in thermal barrier coatings.
Keywords:
CMAS corrosion
finite element simulation
pore morphology
thermal barrier coatings
thermodynamic properties
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