Abstract: CoNiCrAlY alloys have been widely used as bond coats for thermal barrier coating (TBC) systems because of low cost, improved control of composition, and the feasibility to tailor the coatings microstructures. Coatings are in general very thin structures, and therefore it is impossible to characterize the mechanical responses of the materials via conventional mechanical testing methods. Due to this reason, miniature specimen testing methods, such as the small punch test technique, have been developed. This paper presents some of the recent research in evaluating the mechanical properties of the CoNiCrAlY coatings at room and high temperatures, through the use of small punch testing and the developed miniature specimen tensile testing, applicable to a range of temperature, to investigate the elastic-plastic and creep behavior as well as ductile-brittle transition temperature (DBTT) behavior. An inverse procedure was developed to derive the mechanical properties from such tests for the coating materials. A two-layer specimen test method is also described. The key findings include: 1) the temperature-dependent coating properties can be accurately determined by the miniature tensile testing within a wide range of temperature; 2) consistent DBTTs can be identified by both the SPT and miniature tensile tests (~ 650 °C); and 3) the FE SPT modelling has shown good capability of simulating the early local cracking. In general, the temperature-dependent material behaviors of the CoNiCrAlY coating has been effectively characterized using miniature specimen testing and inverse method.
Abstract: In this work, methods for determining creep properties which can be used to represent the full life until failure from miniature specimen creep tests based on analytical solutions are presented. Examples used to demonstrate the application of the methods include a miniature rectangular thin beam specimen creep test under three-point bending and a miniature two-material tensile specimen creep test subjected to a steady load. Mathematical expressions for deflection and creep strain rate of the two specimens were presented for the Kachanov-Rabotnov creep damage model. On this basis, an inverse procedure was developed which has potential applications for deriving the full life creep damage constitutive properties from a very small volume of material, in particular, for various microstructure constitutive regions, e.g. within heat-affected zones of power plant pipe weldments. Further work on validation and improvement of the method is addressed.
Abstract: This paper describes a new approach which can be
used to interpret the experimental creep deformation data obtained
from miniaturized thin plate bending specimen test to the
corresponding uniaxial data based on an inversed application of the
reference stress method. The geometry of the thin plate is fully
defined by the span of the support, l, the width, b, and the thickness,
d. Firstly, analytical solutions for the steady-state, load-line creep
deformation rate of the thin plates for a Norton’s power law under
plane stress (b→0) and plane strain (b→∞) conditions were obtained,
from which it can be seen that the load-line deformation rate of the
thin plate under plane-stress conditions is much higher than that
under the plane-strain conditions. Since analytical solution is not
available for the plates with random b-values, finite element (FE)
analyses are used to obtain the solutions. Based on the FE results
obtained for various b/l ratios and creep exponent, n, as well as the
analytical solutions under plane stress and plane strain conditions, an
approximate, numerical solutions for the deformation rate are
obtained by curve fitting. Using these solutions, a reference stress
method is utilised to establish the conversion relationships between
the applied load and the equivalent uniaxial stress and between the
creep deformations of thin plate and the equivalent uniaxial creep
strains. Finally, the accuracy of the empirical solution was assessed
by using a set of “theoretical” experimental data.
Abstract: This paper presents a method for determining the
uniaxial tensile properties such as Young-s modulus, yield strength
and the flow behaviour of a material in a virtually non-destructive
manner. To achieve this, a new dumb-bell shaped miniature
specimen has been designed. This helps in avoiding the removal of
large size material samples from the in-service component for the
evaluation of current material properties. The proposed miniature
specimen has an advantage in finite element modelling with respect
to computational time and memory space. Test fixtures have been
developed to enable the tension tests on the miniature specimen in a
testing machine. The studies have been conducted in a chromium
(H11) steel and an aluminum alloy (AR66). The output from the
miniature test viz. load-elongation diagram is obtained and the finite
element simulation of the test is carried out using a 2D plane stress
analysis. The results are compared with the experimental results. It is
observed that the results from the finite element simulation
corroborate well with the miniature test results. The approach seems
to have potential to predict the mechanical properties of the
materials, which could be used in remaining life estimation of the
various in-service structures.