Abstract The thermal barrier coating system (TBCs) has complex structure and works in severe service environment. Erosion is one of the main factors causing the failure of TBCs. In the present study, the particle erosion process of atmospheric plasma sprayed (APS) thermal barrier coatings at elevated temperature was simulated by the finite element method. The effects of interface morphology on the penetration depth, particle ricochet velocity and interface stress state were studied, and the key parameters such as particle size, initial velocity and erosion position were also considered. The cosine curve with constant wavelength and varying amplitude was used to represent different interface roughness of TBCs. The results show that the interface morphology has little effect on the penetration depth of top coat (TC) and the particle ricochet velocity. The influence of particle erosion position related to the interface morphology is obvious. Basically, the greater the interface roughness is, the more violent the interfacial stress fluctuation is. During the erosion process, the stress in the middle of the interface is significantly higher than that at other positions. These results facilitate understanding of the particle erosion failure mechanism of APS TBCs. The influence of interface morphology should be considered in erosion research.

中文翻译：

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界面形貌对热障涂层侵蚀失效的影响

摘要 热障涂层系统（TBCs）结构复杂，工作环境恶劣。侵蚀是导致TBC失效的主要因素之一。在本研究中，大气等离子喷涂 (APS) 热障涂层在高温下的颗粒侵蚀过程通过有限元方法进行了模拟。研究了界面形态对穿透深度、颗粒弹跳速度和界面应力状态的影响，并考虑了颗粒尺寸、初始速度和侵蚀位置等关键参数。具有恒定波长和变化幅度的余弦曲线用于表示TBCs的不同界面粗糙度。结果表明，界面形貌对面漆穿透深度（TC）和颗粒弹跳速度影响不大。与界面形态相关的颗粒侵蚀位置的影响是明显的。基本上，界面粗糙度越大，界面应力波动越剧烈。在侵蚀过程中，界面中间的应力明显高于其他位置。这些结果有助于理解 APS TBC 的颗粒侵蚀失效机制。侵蚀研究应考虑界面形貌的影响。在侵蚀过程中，界面中间的应力明显高于其他位置。这些结果有助于理解 APS TBC 的颗粒侵蚀失效机制。侵蚀研究应考虑界面形态的影响。在侵蚀过程中，界面中间的应力明显高于其他位置。这些结果有助于理解 APS TBC 的颗粒侵蚀失效机制。侵蚀研究应考虑界面形貌的影响。