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<p>Corrosion failure induced by molten CaO-MgO-Al<sub>2</sub>O<sub>3</sub>-SiO<sub>2</sub> (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&#xa0;W/mm<sup>2</sup>, while stress concentration at pore tips intensifies with <i>S</i><sub>max</sub> reaching 155&#xa0;MPa. Under smaller aspect ratios, the shear stress exhibits significant fluctuations, with peak values approaching 120&#xa0;MPa. Enlarged circular pores induce localized heat flux concentration, whereas elliptical pores cause stronger <i>S</i><sub>max</sub> 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.</p>

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Effect of CMAS-Filled Pore Morphology on Thermomechanical Behavior of Thermal Barrier Coatings

  • 期刊论文

  • 发表日期：

    2026年8月2日

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  • Zhimin Yao,
  • Wangzhuo Hu,
  • Yining Li,
  • Ranxing Leng

摘要

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.