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<p>This study addresses thermal stress challenges in dense CoNiCrAlY thick coatings applied to turbine outer ring blocks. Combining finite element simulation and experimental methods, a systematic study was conducted to investigate the effects of coating thickness (0.6–1.2&#xa0;mm), operating temperature (800–1100&#xa0;°C), and ring block substrate curvature (0–1/30&#xa0;mm<sup>−1</sup>) on instantaneous thermal stress distribution during thermal shock cooling. Results demonstrate that longitudinal tensile stress concentrates predominantly at interface edges and adjacent side regions across all thicknesses and temperatures. Increasing coating thickness or temperature significantly elevates peak tensile stress at interfaces and sides. Conversely, greater ring block curvature substantially reduces these interfacial and side peak stresses, but intensifies surface tensile stress. The maximum tensile stress in the coating system exhibits a non-monotonic trend, reaching a minimum at 1/45&#xa0;mm<sup>−1</sup> curvature.</p>

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Finite Element Analysis of Thermal Stress in Dense CoNiCrAlY Thick Coatings on Ring Block Substrates under Thermal Shock Cooling

  • 期刊论文

  • 发表日期：

    2026年2月18日

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  • Shuting Zhang,
  • Yuxin Guo,
  • Haitao Yun,
  • Peixuan Ouyang

摘要

This study addresses thermal stress challenges in dense CoNiCrAlY thick coatings applied to turbine outer ring blocks. Combining finite element simulation and experimental methods, a systematic study was conducted to investigate the effects of coating thickness (0.6–1.2 mm), operating temperature (800–1100 °C), and ring block substrate curvature (0–1/30 mm−1) on instantaneous thermal stress distribution during thermal shock cooling. Results demonstrate that longitudinal tensile stress concentrates predominantly at interface edges and adjacent side regions across all thicknesses and temperatures. Increasing coating thickness or temperature significantly elevates peak tensile stress at interfaces and sides. Conversely, greater ring block curvature substantially reduces these interfacial and side peak stresses, but intensifies surface tensile stress. The maximum tensile stress in the coating system exhibits a non-monotonic trend, reaching a minimum at 1/45 mm−1 curvature.