Thermal shock life prediction method and device for thermal barrier coating based on digital twinning and medium

Abstract

The invention discloses a method for predicting the thermal shock life of a thermal barrier coating based on digital twinning, and the method comprises the steps: extracting the thermal barrier coating characteristics of one or more different thermal barrier coating samples, establishing one or more thermal shock life simulation models of the thermal barrier coatings with different microstructures at least partially based on the extracted thermal barrier coating features in combination with specified conditions during the thermal shock assessment process of the corresponding thermal barrier coating, detecting a crack parameter and a stress state at the ceramic layer and bonding layer interface of the respective thermal barrier coating and generating a first data set, updating the digital twin model based at least in part on the first data set and a second data set associated with an evolution of a physical characteristic of the respective thermal barrier coating, and performing thermal shock life prediction of the thermal barrier coating based on the updated digital twin model. Numerous other aspects are also provided.

Description

Technical Field

[0001] The present invention relates to the field of aero-engines, and more specifically to a method, device and medium for predicting thermal shock life of thermal barrier coatings based on digital twins. Background Art

[0002] The hot end components of aircraft engines and gas turbines usually need to withstand harsh and complex service conditions during their service, with high temperature thermal shock and corrosion being particularly prominent. These factors seriously threaten the service life of the hot end components. Therefore, the protection of these metal-based hot end components is of great significance. Thermal barrier coatings (TBCs) are widely used in the thermal protection field of aircraft engines and gas turbines due to their excellent high-temperature thermal insulation properties and oxidation corrosion resistance. The application of thermal barrier coatings can greatly improve the thermal efficiency of the engine and the performance and life limit of the hot end components. Among them, plasma spraying technology is widely used in the preparation of thermal barrier coatings due to its excellent process flexibility and application cost advantages. However, due to the harsh service conditions, once the thermal barrier coating fails to peel off, it will cause the underlying metal components to burn rapidly and fail, causing devastating effects. Therefore, the life prediction of thermal barrier coatings is the key to ensuring the safe service of hot end components of aircraft engines and gas turbines. Since the performance of thermal barrier coatings is closely related to factors such as parameters and microstructure during the preparation process, and the service conditions of thermal barrier coatings are usually multi-field coupled conditions, its life prediction and health management is a challenging task.

[0003] Digital twin technology is to obtain real physical models, sensor updates, operation history and other multivariate data and map them to virtual twin models, and through continuous interaction between physical entities and virtual models, the use and life of key components are evaluated in real time. At present, digital twin technology has become a key technology in the field of industrial production and intelligent manufacturing. Existing technologies mainly focus on the fatigue life prediction of the base metal materials of hot end components (such as aircraft engine turbine disks and turbine blades), and there is no prediction of the thermal shock life of thermal barrier coatings. As an important thermal insulation component on the surface of the hot end components of the metal matrix, the high-temperature thermal shock life of the thermal barrier coating is of great significance to the structural integrity and safe operation of the components. Therefore, it is urgent to propose a method that introduces the idea of ​​digital twins to realize interactive feedback between physical entities and virtual models based on the actual service conditions and the differences in coating structure caused by different thermal barrier coating preparation processes to accurately predict the thermal shock life of thermal barrier coatings.

[0004] The present application proposes a method, device and medium for predicting the thermal shock life of thermal barrier coatings based on digital twins, which can predict the high-temperature thermal shock life of thermal barrier coatings in real time and accurately, and provide a basis for the structural design of subsequent thermal barrier coating systems. Summary of the invention

[0005] A brief summary of one or more aspects is given below to provide a basic understanding of these aspects. This summary is not an exhaustive overview of all conceived aspects, and is neither intended to identify the key or critical elements of all aspects nor to define the scope of any or all aspects. Its only purpose is to give some concepts of one or more aspects in a simplified form as a prelude to a more detailed description given later.

[0006] In order to solve the above problems, various aspects of the present application propose a method, device and medium for predicting the thermal shock life of thermal barrier coatings based on digital twins.

[0007] In one aspect of the present disclosure, a method for predicting the thermal shock life of a thermal barrier coating based on a digital twin is disclosed, comprising: extracting thermal barrier coating features of one or more different thermal barrier coating samples, the thermal barrier coating features including the microstructure and thermodynamic parameters of the corresponding thermal barrier coating; determining specified conditions during a thermal shock assessment process for the corresponding thermal barrier coating; establishing one or more thermal shock life simulation models of thermal barrier coatings with different microstructures based at least in part on the extracted thermal barrier coating features and in combination with the specified conditions; during a synchronous thermal shock assessment process, detecting cracks at the interface between a ceramic layer and a bonding layer of the corresponding thermal barrier coating Parameters and stress states, and generate a first data set associated with the evolution of crack parameters and stress states at the interface between the ceramic layer and the bonding layer of the corresponding thermal barrier coating; interact the first data set with a corresponding thermal shock life simulation model in one or more thermal shock life simulation models in real time to generate a digital twin model of the corresponding thermal barrier coating; update the digital twin model at least partially based on a second data set associated with the evolution of physical characteristics of the corresponding thermal barrier coating during different time periods during the thermal shock assessment process; and perform the thermal shock life prediction of the thermal barrier coating based on the updated digital twin model.

[0008] Preferably, extracting the microstructure of the thermal barrier coating includes: using computational micromechanics methods to convert a scanning electron microscope image reflecting the microstructure inside the ceramic layer into a digital image with m×n pixels; using image tracking technology to convert the digital image of the thermal barrier coating prepared under different preparation parameters into a vector image; importing the digital image into modeling software to convert it into a planar entity.

[0009] Preferably, the specified conditions include one or more of the following: sample heating time, sample heating temperature, sample insulation time, sample cooling time, and types of sample heating and cooling media.

[0010] Preferably, during the thermal shock assessment process of the thermal barrier coating sample, the operating conditions and / or environmental parameters of the thermal shock assessment process are kept consistent with the operating conditions / environmental parameters input into the thermal shock life simulation model.

[0011] Preferably, generating a first data set associated with the corresponding thermal barrier coating includes: using a terahertz time-domain spectroscopy monitoring system in a reflection mode to detect the crack parameters and stress state at the interface between the ceramic layer and the bonding layer of all thermal barrier coating samples during the thermal shock assessment process, and using the detected data as the first data set, and wherein the first data set is associated with the timestamp when the data is generated.

[0012] Preferably, detecting the crack parameters and stress state at the interface between the ceramic layer and the bonding layer of the corresponding thermal barrier coating comprises: emitting a femtosecond pulse laser from a femtosecond laser of a terahertz time-domain spectroscopy monitoring system, wherein the femtosecond pulse laser is split into a first light beam and a second light beam, wherein the first light beam is a pump light, which passes through an optical delay line module of the terahertz time-domain spectroscopy monitoring system and is incident on a terahertz emitter module of the terahertz time-domain spectroscopy monitoring system, wherein a photoconductive antenna is excited by the pump light and radiates a terahertz pulse, wherein the terahertz pulse enters a spatial optical path transmission system of the terahertz time-domain spectroscopy monitoring system, and is transmitted to a terahertz transmitter module of the terahertz time-domain spectroscopy monitoring system. The barrier coating sample surface is reflected, and the second light beam is the detection light, which is emitted from the spectroscope of the terahertz time-domain spectroscopy monitoring system to drive the terahertz detection source; and the receiver module of the terahertz time-domain spectroscopy monitoring system uses a wavelet signal processing method to decompose the signal, obtain the approximate coefficients and detail coefficients after the signal decomposition, reconstruct and filter them, and then perform frequency domain deconvolution through a Hanning window function, so as to detect the first data set associated with the evolution of crack parameters and stress state at the interface between the ceramic layer and the bonding layer during the thermal shock assessment process as the cycle of thermal shock assessment is executed.

[0013] Preferably, generating the digital twin model of the corresponding thermal barrier coating further comprises: inputting the first data set into the thermal shock life simulation model to modify the first parameter set of the thermal shock life simulation model associated with the evolution of crack parameters and stress state.

[0014] Preferably, the digital twin model includes one or more of a thermal-mechanical coupling analysis model, a stress field analysis model, and a structural damage evolution model.

[0015] Preferably, updating the digital twin model based on the second data set includes: inputting the actually measured second data set into the digital twin model to update the second parameter set of the digital twin model associated with the physical feature.

[0016] Preferably, the evolution of the physical characteristics of the thermal barrier coating includes the evolution of microstructure, mechanical properties, and damage state, and further includes: the evolution of the porosity of the ceramic layer during the thermal shock process, the evolution of the hardness, elastic modulus, and fracture toughness of the ceramic layer, the evolution of the crack length in the ceramic layer, and the evolution of the spalling area in the ceramic coating.

[0017] In another aspect of the present disclosure, a device for predicting the thermal shock life of a thermal barrier coating based on a digital twin is disclosed, comprising a processor and a memory, wherein the memory stores program instructions; the processor executes the program instructions to implement any of the above methods.

[0018] In another aspect of the present disclosure, a non-transitory computer-readable storage medium storing instructions is disclosed. When the instructions are executed by a computer, the computer performs a method for predicting the thermal shock life of a thermal barrier coating based on a digital twin as described in any one of the above.

[0019] The present invention summary is provided to introduce some concepts in a simplified form, which will be further described in the following detailed description. The present invention summary is not intended to identify the key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects, features and / or advantages of each embodiment will be set forth in part in the following description, and will be apparent in part from the description, or can be learned through the practice of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to understand in detail the manner in which the above features of the present invention are used, the above briefly summarized contents may be described in more detail with reference to various embodiments, some of which are shown in the accompanying drawings. It should be noted, however, that the accompanying drawings only show certain typical aspects of the present invention and should not be considered to limit its scope, as the description may allow for other equally effective aspects. In the accompanying drawings, similar reference numerals are always similarly identified. It should be noted that the drawings described are only schematic and non-restrictive. In the drawings, the sizes of some components may be exaggerated and are not drawn to scale for illustrative purposes.

[0021] Figure 1 An example of a flowchart of a method for predicting thermal shock life of a plasma sprayed thermal barrier coating based on digital twin according to an embodiment of the present invention is explained.

[0022] Figure 2 An example of a technical roadmap for a method for predicting thermal shock life of a plasma sprayed thermal barrier coating based on digital twin according to an embodiment of the present invention is explained.

[0023] Figure 3An example of a thermal barrier coating microstructure prepared by plasma spraying according to an embodiment of the present invention is illustrated.

[0024] Figure 4 An example of a practical thermal shock assessment flow chart for plasma sprayed thermal barrier coatings according to an embodiment of the present invention is explained.

[0025] Figure 5 An example of a working schematic diagram of a terahertz time-domain spectroscopy monitoring system according to an embodiment of the present invention is explained. DETAILED DESCRIPTION

[0026] In order to make the purpose, technical scheme and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with specific embodiments and with reference to the accompanying drawings. In the following detailed description, many specific details are set forth to provide a thorough understanding of the described exemplary embodiments. However, it is obvious to those skilled in the art that the described embodiments can be practiced without some or all of these specific details. In other exemplary embodiments, well-known structures or processing steps are not described in detail to avoid unnecessarily obscuring the concepts of the present disclosure.

[0027] In this specification, unless otherwise specified, the term "A or B" used throughout the specification refers to "A and B" and "A or B" rather than meaning that A and B are exclusive.

[0028] The hot end components of aircraft engines and gas turbines usually need to withstand harsh and complex service conditions during service, and high temperature thermal shock and corrosion are particularly prominent. These factors seriously threaten the service life of hot end components. Therefore, the protection of these metal-based hot end components is of great significance. Thermal barrier coatings are widely used in the thermal protection field of aircraft engines and gas turbines due to their excellent high-temperature thermal insulation performance and oxidation corrosion resistance. The application of thermal barrier coatings can greatly improve the thermal efficiency of the engine and the performance and life limit of hot end components. Among them, plasma spraying technology is widely used in the preparation of thermal barrier coatings due to its excellent process flexibility and application cost advantages. However, due to the harsh service conditions, once the thermal barrier coating fails to peel off, it will cause the underlying metal parts to burn and fail rapidly, causing devastating effects. Therefore, the life prediction of thermal barrier coatings is the key to ensuring the safe service of hot end components of aircraft engines and gas turbines. Since the performance of thermal barrier coatings is closely related to the parameters and microstructure during its preparation process, and the service conditions of thermal barrier coatings are usually multi-field coupling conditions, its life prediction and health management is a challenging task.

[0029] Digital twin technology is to obtain real physical models, sensor updates, operation history and other multivariate data and map them to virtual twin models, and through continuous interaction between physical entities and virtual models, the use and life of key components are evaluated in real time. At present, digital twin technology has become a key technology in the field of industrial production and intelligent manufacturing. Existing technologies mainly focus on the fatigue life prediction of the base metal materials of hot end components (such as aircraft engine turbine disks and turbine blades), and there is no prediction of the thermal shock life of thermal barrier coatings. As an important thermal insulation component on the surface of the hot end components of the metal matrix, the high-temperature thermal shock life of the thermal barrier coating is of great significance to the structural integrity and safe operation of the components. Therefore, it is urgent to propose a method that introduces the idea of ​​digital twins to realize interactive feedback between physical entities and virtual models based on the actual service conditions and the differences in coating structure caused by different thermal barrier coating preparation processes to accurately predict the thermal shock life of thermal barrier coatings.

[0030] This application proposes a method, device and medium for predicting the thermal shock life of thermal barrier coatings based on digital twins, which can accurately predict the high-temperature thermal shock life of thermal barrier coatings in real time and provide a basis for the structural design of subsequent thermal barrier coating systems. Figures 1 to 5 The method, device and medium for predicting thermal shock life of plasma sprayed thermal barrier coating based on digital twin according to one embodiment of the present invention are explained. Figure 1 An example of a flowchart of a method for predicting thermal shock life of a plasma sprayed thermal barrier coating based on digital twin according to an embodiment of the present invention is explained; Figure 2 An example of a technical roadmap for a method for predicting thermal shock life of a plasma sprayed thermal barrier coating based on digital twins according to an embodiment of the present invention is explained; Figure 3 An example of a thermal barrier coating microstructure prepared by plasma spraying according to an embodiment of the present invention is explained; Figure 4 An example of a flow chart for actual thermal shock assessment of a plasma sprayed thermal barrier coating according to an embodiment of the present invention is explained; Figure 5 An example of a working schematic diagram of a terahertz time-domain spectroscopy monitoring system according to an embodiment of the present invention is explained.

[0031] Figure 1 The flowchart of the method for predicting thermal shock life of plasma sprayed thermal barrier coating based on digital twin provided by the present invention specifically includes the following steps:

[0032] S1: extracting thermal barrier coating characteristics of one or more different thermal barrier coating samples, wherein the thermal barrier coating characteristics include the microstructure and thermodynamic parameters of the corresponding thermal barrier coating. In an embodiment of the present application, for example, the microstructure and mechanical and thermal parameter information of the plasma sprayed thermal barrier coating prepared under different parameters can be obtained based on a large number of actual samples.

[0033] Specifically, the thermal barrier coating samples are obtained based on a large number of different preparation process parameters, and the samples are processed by standard metallographic process and the internal microstructure of the ceramic layer prepared under different parameters is obtained by scanning electron microscopy (such as Figure 2 S1-1, the first thermal barrier coating TBC1 and the second thermal barrier coating TBC2).

[0034] In particular, if Figure 3 As shown in the figure, the plasma sprayed thermal barrier coating sample is formed by fixing the ceramic layer 31 to the metal substrate 33 by the bonding layer 32. Among them, the ceramic layer 31 plays the main role of heat insulation, and the coating is prepared by plasma spraying, with a thickness of 50 to 500 μm. The metal substrate 33 is preferably a nickel-based high-temperature alloy or a single crystal substrate, with a thickness of 3 to 6 mm. The metal bonding layer 32 is located between the metal substrate 33 and the ceramic layer 31, which plays the role of increasing the adhesion between the ceramic layer and the metal substrate and increasing the high-temperature oxidation resistance of the substrate.

[0035] Preferably, the preparation method of the metal bonding layer includes but is not limited to plasma spraying and / or supersonic flame spraying, and the thickness thereof is 50 to 200 μm.

[0036] Furthermore, the computational micromechanics method (CMM) is used to convert the scanning electron microscope image reflecting the internal microstructure of the ceramic layer into a digital image with m×n pixels, which can be represented as a matrix A:

[0037]

[0038] In particular, the digital images of the coatings prepared under different preparation parameters are converted into vector graphics (e.g. Figure 2 S1-2 in, the converted first thermal barrier coating TBC1 and the converted second thermal barrier coating TBC2).

[0039] Specifically, the digital image is imported into modeling software (including but not limited to CAD / SolidWorks, etc.) and converted into a plane entity, thereby realizing the extraction of microstructure features of the thermal barrier coating.

[0040] The indentation method, laser flash method, linear thermal expansion coefficient method and drainage method are respectively used to measure and record material parameters including at least elastic modulus, thermal diffusion coefficient, thermal diffusion coefficient, density and the like of thermal barrier coating samples with different microstructures.

[0041] S2: Determine the specified conditions during the thermal shock assessment process of the corresponding thermal barrier coating. In the embodiments of the present application, for example, temperature and time related conditions during the thermal shock assessment process of the thermal barrier coating may be introduced.

[0042] Specifically, considering the operating conditions during the actual thermal shock assessment of thermal barrier coatings, the conditions introduced during the thermal shock assessment process include actual operating parameters such as sample heating time, heating temperature, sample insulation time, sample cooling time, and types of heating and cooling media.

[0043] Preferably, the heating medium includes but is not limited to oxygen, propane / aviation kerosene, and the cooling medium includes but is not limited to compressed air.

[0044] like Figure 4 As shown, during the thermal shock performance assessment of the actual sample, the test device achieves the effect of heating the sample 42 through 41 oxygen / propane, and detects the temperature change of the sample surface during the thermal shock assessment test cycle in real time through 43 infrared temperature sensor. When the sample surface temperature meets the set temperature condition, 44 thermal shock assessment is performed. When the sample temperature does not meet the set temperature, the flow rate of the heating medium is adjusted through 45 so that the actual temperature of the sample meets the set condition.

[0045] S3: Establish one or more thermal shock life simulation models of thermal barrier coatings with different microstructures based at least in part on the extracted thermal barrier coating features and in combination with the specified conditions. In an embodiment of the present application, for example, thermal barrier coating models with different microstructure features and thermodynamic parameter information can be obtained, and thermal shock assessment conditions can be combined to establish thermal shock life simulation models of thermal barrier coatings with different microstructure features (such as Figure 2 S3 in, simulation model of the first thermal barrier coating TBC1 and the second thermal barrier coating TBC2).

[0046] In particular, the simulation software used here includes but is not limited to finite element simulation software such as Ansys or Abaqus.

[0047] S4: During the simultaneous thermal shock assessment process, crack parameters and stress states at the interface between the ceramic layer and the bonding layer of the corresponding thermal barrier coating are detected, and a first data set associated with the evolution of crack parameters and stress states at the interface between the ceramic layer and the bonding layer of the corresponding thermal barrier coating is generated. In an embodiment of the present application, for example, a terahertz time-domain spectroscopy monitoring system (such as a terahertz time-domain spectroscopy monitoring system) can be used in the simultaneous actual thermal shock assessment process. Figure 2 The data associated with the evolution of crack parameters (e.g., crack length, width, depth, etc.) and stress state at the interface between the ceramic layer and the bonding layer of the sample during the thermal shock assessment (as shown in S4 in the figure) are detected. The data obtained by the detection can be referred to as a first data set. Additionally or alternatively, the first data set can be associated with a timestamp when the data is generated, and accordingly, can be stored in a storage module.

[0048] Specifically, in S4, during the actual high-temperature thermal shock test of all thermal barrier coating samples, the test conditions / environmental parameters are consistent with the conditions / environmental parameters input in the simulation model. Furthermore, the terahertz time-domain spectroscopy technology is used in the reflection mode to perform real-time detection of the crack parameters (e.g., crack length) and stress state at the interface between the ceramic layer and the bonding layer in all thermal barrier coating samples during the actual thermal shock test to obtain a real-time data set.

[0049] In particular, if Figure 5 As shown, the terahertz time domain spectroscopy monitoring system includes a femtosecond laser module 51, a terahertz time domain spectroscopy (THz-TDS) module 52, a delay line module 53, a transmitter module 54 and a receiver module 55. The femtosecond pulse laser emitted by the femtosecond laser 51 will be divided into two beams of light, one of which is the pump light. After passing through the optical delay line module 53, it is incident on the terahertz transmitter module 54. The photoconductive antenna radiates the terahertz pulse after being excited by the pump light. The terahertz pulse enters the spatial optical path transmission system and is reflected on the sample surface; the other beam is the detection light, which is emitted from the spectroscope to drive the terahertz detection source. In the receiver module 55, the signal is decomposed by using the wavelet signal processing method, and the approximate coefficients and detail coefficients after the signal decomposition are obtained for reconstruction and filtering, and then the frequency domain deconvolution is performed through the Hanning window function, so as to extract the evolution of the crack length and stress state at the interface between the ceramic layer and the bonding layer during the actual thermal shock assessment process as the thermal shock cycle proceeds.

[0050] In particular, the femtosecond laser pulse width, central wavelength, repetition frequency, spectrum half-width and output power include but are not limited to 80fs, 800nm, 76MHz, 11nm and 1.1W respectively. In order to ensure the reliability of the test, each sample is tested at 5 non-overlapping positions of the light spots, and the data set of each position is obtained by 256 scans, and the average value is finally taken. It should be understood that by using terahertz time-domain spectroscopy technology to detect the crack parameters (e.g., crack length) and stress state at the interface between the ceramic layer and the bonding layer in the thermal barrier coating sample, the effect of not destroying the thermal barrier coating sample can be achieved.

[0051] S5: The first data set is interacted with a corresponding thermal shock life simulation model in one or more thermal shock life simulation models in real time to generate a digital twin model of the corresponding thermal barrier coating. In an embodiment of the present application, for example, the data of the evolution of crack parameters and stress state at the interface between the ceramic layer and the bonding layer during the actual thermal shock assessment detected by the terahertz time-domain spectroscopy monitoring system can be interacted with the simulation model in real time to obtain a digital twin model of the thermal barrier coating (such as Figure 2 ).

[0052] Specifically, the data of crack parameters and stress evolution at the interface between the ceramic layer and the bonding layer obtained in S4 based on terahertz monitoring are input into the simulation model obtained in S3, so as to correct the first parameter set of the simulation parameter model associated with the evolution of crack parameters and stress state. In the embodiment of the present application, the crack parameters and stress evolution results monitored by terahertz can be used to replace the first parameter set of the digital twin model. Thus, the stress state of the thermal barrier coating sample during the thermal shock assessment process ( Figure 2 S5-2) and crack evolution ( Figure 2 S5-1 in the above), thereby generating a revised digital twin model. Additionally or alternatively, the digital twin model is a model with real-time data attributes. Additionally or alternatively, the digital twin model is updated periodically or aperiodically at different time periods during the actual thermal shock assessment process.

[0053] Preferably, in an embodiment of the present application, the digital twin model described in S5 includes but is not limited to a thermal-mechanical coupling analysis model, a stress field analysis model, a structural damage evolution model, or a combination thereof.

[0054] S6: updating the digital twin model at least partially based on a second data set associated with the evolution of the physical characteristics of the corresponding thermal barrier coating during different time periods during the thermal shock assessment process. In an embodiment of the present application, for example, the digital twin model can be updated based on the physical characteristics of the thermal barrier coating detected during the actual assessment process, such as microstructure evolution, mechanical property evolution data, and coating spalling damage evolution data.

[0055] Specifically, a thermal shock simulation test device is used to set the thermal shock assessment conditions according to the conditions described in S2, and the sample is repeatedly subjected to a high-temperature thermal shock cycle test until the coating fails due to peeling, and the failure condition threshold is determined to be that the peeling area is greater than 20% of the total coating area. It should be understood that other numerical failure condition thresholds can also be used. By sampling and testing actual samples of thermal barrier coatings in different time periods of high-temperature thermal shock assessment, the microstructure evolution, mechanical property evolution, and damage state evolution data of the thermal barrier coating samples during the high-temperature thermal shock process described in S6 can be obtained, and this data can be referred to as the second data set.

[0056] In particular, the evolution of these structural and performance parameters at least includes the evolution of the porosity of the ceramic layer during high-temperature thermal shock, the evolution of the hardness, elastic modulus, fracture toughness of the ceramic layer, the evolution of the crack length in the ceramic layer, and the evolution of the spalling area in the ceramic coating.

[0057] Further, these measured results are input into the digital twin model, so as to further update the second parameter set associated with the physical features of the digital twin model, thereby obtaining a more accurate and real-time synchronized digital twin model. In an embodiment of the present application, the measured results can be used to replace the second parameter set associated with the physical features of the digital twin model. It should be understood that the correction and update of the aforementioned S5 and S6 can be performed synchronously or in any order.

[0058] S7: Execute the thermal shock life prediction of the thermal barrier coating based on the updated digital twin model. For example, the thermal shock life prediction can be associated with the preparation process parameters of the thermal barrier coating. In an embodiment of the present application, for example, a digital twin life prediction model from the preparation process parameters of the plasma sprayed thermal barrier coating to the thermal shock life can be established according to the revised digital twin model, and the model can be used to perform thermal shock life prediction.

[0059] Specifically, Figure 2 As shown in the figure, the digital twin model is further corrected and updated through the performance evolution data of the actual thermal shock assessment of the sample, so that the thermal shock life prediction of the thermal barrier coating can be performed more accurately.

[0060] In particular, the above method can be used for engine thermal barrier coating testing or in-service health monitoring.

[0061] The present invention provides a method for predicting the thermal shock life of a plasma sprayed thermal barrier coating based on digital twins. The method detects the crack length and stress state evolution at the interface between the ceramic layer and the bonding layer of thermal barrier coating samples with different microstructures under different process plasma spraying parameters through terahertz time-domain spectroscopy, and uses the detection data to correct the finite element simulation model, thereby obtaining a digital twin model with real-time characteristics. In addition, the digital twin model is continuously updated and corrected through the measured data of the sample microstructure, mechanical properties, etc. during the thermal shock assessment, thereby obtaining a method for predicting the thermal shock life of a plasma sprayed thermal barrier coating. Thus, a full-cycle thermal barrier coating life prediction method from plasma sprayed thermal barrier coating process parameters to thermal shock life is established, thereby guiding the preparation of actual thermal barrier coatings.

[0062] Moreover, an embodiment of the present application further discloses a computer-readable storage medium including computer-executable instructions stored thereon, and when the computer-executable instructions are executed by a processor, the processor executes the methods of the embodiments of this document.

[0063] In addition, an embodiment of the present application further discloses a device, which includes a processor and a memory storing computer-executable instructions. When the computer-executable instructions are executed by the processor, the processor executes the methods of the embodiments of this document.

[0064] In addition, an embodiment of the present application further discloses a device for predicting the thermal shock life of a thermal barrier coating based on a digital twin, the device comprising: a device for extracting thermal barrier coating characteristics of one or more different thermal barrier coating samples, the thermal barrier coating characteristics comprising a microstructure and thermodynamic parameters of the corresponding thermal barrier coating; a device for determining specified conditions during a thermal shock assessment process for the corresponding thermal barrier coating; a device for establishing one or more thermal shock life simulation models of thermal barrier coatings with different microstructures based at least in part on the extracted thermal barrier coating characteristics and in combination with the specified conditions; a device for detecting cracks at the interface between a ceramic layer and a bonding layer of the corresponding thermal barrier coating during a synchronous thermal shock assessment process. The invention relates to a device for generating a first data set associated with the evolution of crack parameters and stress states at the interface between the ceramic layer and the bonding layer of the corresponding thermal barrier coating; a device for interacting the first data set with a corresponding thermal shock life simulation model in one or more thermal shock life simulation models in real time to generate a digital twin model of the corresponding thermal barrier coating; a device for updating the digital twin model at different time periods during the thermal shock assessment process, at least in part based on a second data set associated with the evolution of physical characteristics of the corresponding thermal barrier coating; and a device for performing thermal shock life prediction of the thermal barrier coating based on the updated digital twin model.

[0065] The above describes a method, device and medium for predicting thermal shock life of thermal barrier coatings based on digital twins according to the present invention. Compared with the prior art, the method of the present invention has at least the following advantages:

[0066] (1) Considering the influence of coating microstructure differences caused by different preparation process parameters on the high temperature thermal shock life of thermal barrier coating system;

[0067] (2) Using terahertz time-domain spectroscopy monitoring technology, a digital twin model was established that takes into account actual thermal shock conditions, actual microstructure, and performance evolution;

[0068] (3) By comparing and interacting with measured data, the digital twin model can be updated and corrected, and the influence of complex factors such as microstructure, material properties, and crack evolution on the thermal shock life of thermal barrier coatings can be comprehensively considered;

[0069] (4) Real-time and accurate prediction of the high-temperature thermal shock life of thermal barrier coatings, providing a basis for the subsequent structural design of thermal barrier coating systems.

[0070] Reference has been made throughout the specification to "an embodiment" to mean that a particular described feature, structure, or characteristic is included in at least one embodiment. Thus, the use of these phrases may refer to more than just one embodiment. Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0071] The various steps and modules of the methods and devices described above can be implemented with hardware, software, or a combination thereof. If implemented in hardware, the various illustrative steps, modules, and circuits described in conjunction with the present disclosure can be implemented or executed with a general-purpose processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field programmable gate array (FPGA), or other programmable logic components, hardware components, or any combination thereof. The general-purpose processor can be a processor, a microprocessor, a controller, a microcontroller, or a state machine, etc. If implemented in software, the various illustrative steps and modules described in conjunction with the present disclosure can be stored on a computer-readable medium or transmitted as one or more instructions or codes. The software modules that implement the various operations of the present disclosure can reside in a storage medium, such as RAM, flash memory, ROM, EPROM, EEPROM, registers, hard disks, removable disks, CD-ROMs, cloud storage, etc. The storage medium can be coupled to a processor so that the processor can read and write information from / to the storage medium, and execute corresponding program modules to implement the various steps of the present disclosure. Moreover, the software-based embodiments can be uploaded, downloaded, or remotely accessed by appropriate communication means. Such appropriate communications means include, for example, the Internet, the World Wide Web, an intranet, software applications, cable (including fiber optic cables), magnetic communications, electromagnetic communications (including RF microwave and infrared communications), electronic communications, or other such communications means.

[0072] The numerical values ​​given in each embodiment are only examples and are not intended to limit the scope of the present invention. In addition, as an overall technical solution, there are other components or steps that are not listed in the claims or description of the present invention. Moreover, a single name of a component does not exclude other names of the component.

[0073] It should also be noted that these embodiments may be described as a process depicted as a flow chart, flow diagram, structure diagram, or block diagram. Although the flow chart may describe the operations as sequential processes, many of these operations can be performed in parallel or concurrently. In addition, the order of these operations can be rearranged.

[0074] The disclosed methods, devices, and systems should not be limited in any way. On the contrary, the present disclosure covers all novel and non-obvious features and aspects of the various disclosed embodiments (alone and in various combinations and sub-combinations with each other). The disclosed methods, devices, and systems are not limited to any specific aspects or features or combinations thereof, nor do any disclosed embodiments require the existence of any one or more specific advantages or the resolution of specific or all technical problems.

[0075] The present invention is not limited to the above-mentioned specific embodiments, which are merely illustrative and not restrictive. Under the guidance of the present invention, ordinary technicians in this field can make many forms without departing from the scope of protection of the present invention and the claims, all of which belong to the protection scope of the present invention.

[0076] One skilled in the relevant art may recognize that the embodiments may be practiced without one or more of the specific details, or with other methods, resources, materials, etc. In other instances, well-known structures, resources, or operations are not shown or described in detail, merely to obscure aspects of the embodiments.

[0077] Although embodiments and applications have been illustrated and described, it should be understood that the embodiments are not limited to the precise configuration and resources described above. Various modifications, substitutions and improvements that are obvious to those skilled in the art may be made in the arrangement, operation and details of the methods and systems disclosed herein without departing from the scope of the claimed embodiments.

[0078] As used herein, the terms "and," "or," and "and / or" may include various meanings that are also intended to depend, at least in part, on the context in which such terms are used. In general, "or," if used in connection with a list, such as A, B, or C, is intended to mean A, B, and C (where used in an inclusive sense) as well as A, B, or C (where used in an exclusive sense). Additionally, the terms "one or more," as used herein, may be used to describe any feature, structure, or characteristic in the singular, or may be used to describe a plurality of features, structures, or characteristics, or some other combination thereof. It should be noted, however, that this is merely an illustrative example, and claimed subject matter is not limited to this example.

[0079] While what is presently considered to be example features has been illustrated and described, it will be appreciated by those skilled in the art that various other modifications may be made, and equivalents may be substituted, without departing from the claimed subject matter. Additionally, many modifications may be made to adapt a particular scenario to the teachings of the claimed subject matter without departing from the central concept described herein.

Claims

1. A method for predicting thermal shock life of thermal barrier coatings based on digital twins. include: Extracting thermal barrier coating characteristics of one or more different thermal barrier coating samples, wherein the thermal barrier coating characteristics include microstructure and thermodynamic parameters of the corresponding thermal barrier coating; determining specified conditions during a thermal shock assessment process for the corresponding thermal barrier coating; Establishing one or more thermal shock life simulation models of thermal barrier coatings with different microstructures based at least in part on the extracted thermal barrier coating features and in combination with the specified conditions; During the simultaneous thermal shock assessment process, crack parameters and stress states at the interface between the ceramic layer and the bonding layer of the corresponding thermal barrier coating are detected, and a first data set associated with the evolution of the crack parameters and stress states at the interface between the ceramic layer and the bonding layer of the corresponding thermal barrier coating is generated; Interacting the first data set with a corresponding thermal shock life simulation model in one or more thermal shock life simulation models in real time to generate a digital twin model of the corresponding thermal barrier coating; updating the digital twin model based at least in part on a second data set associated with an evolution of a physical characteristic of a corresponding thermal barrier coating at different time periods during the thermal shock assessment process; as well as The thermal shock life prediction of the thermal barrier coating is performed based on the updated digital twin model.

2. The method according to claim 1, It is characterized in that Extracting the microstructure of the thermal barrier coating comprises: Using a computational micromechanics method, the scanning electron microscope image reflecting the microstructure inside the ceramic layer is converted into a digital image with m×n pixels; Converting the digital image of the thermal barrier coating prepared under different preparation parameters into a vector diagram using image tracking technology; The digital image is imported into modeling software and converted into a planar entity.

3. The method according to claim 1, It is characterized in that The specified conditions include one or more of the following: Sample heating time, sample heating temperature, sample insulation time, sample cooling time, sample heating and cooling media types.

4. The method according to claim 1, It is characterized in that During the thermal shock assessment process of the thermal barrier coating sample, the operating conditions and / or environmental parameters of the thermal shock assessment process are kept consistent with the operating conditions / environmental parameters input into the thermal shock life simulation model.

5. The method according to claim 1, It is characterized in that Generating a first data set associated with a corresponding thermal barrier coating comprises: Using a terahertz time-domain spectroscopy monitoring system in a reflection mode, the crack parameters and stress state at the interface between the ceramic layer and the bonding layer of all thermal barrier coating samples during the thermal shock assessment process are detected; and The detected data is used as the first data set, and the first data set is associated with a timestamp when the data is generated.

6. The method according to claim 5, It is characterized in that The crack parameters and stress state detected at the interface between the ceramic layer and the bonding layer of the corresponding thermal barrier coating include: The femtosecond laser of the terahertz time-domain spectroscopy monitoring system emits femtosecond pulse laser. The femtosecond pulse laser is split into a first light beam and a second light beam, wherein the first light beam is a pump light, which is incident on a terahertz transmitter module of the terahertz time-domain spectroscopy monitoring system after passing through an optical delay line module of the terahertz time-domain spectroscopy monitoring system, and a photoconductive antenna radiates a terahertz pulse after being excited by the pump light, and the terahertz pulse enters a spatial optical path transmission system of the terahertz time-domain spectroscopy monitoring system and is reflected on the surface of the thermal barrier coating sample, and wherein the second light beam is a detection light, which is emitted from a spectroscope of the terahertz time-domain spectroscopy monitoring system to drive a terahertz detection source; and The receiver module of the terahertz time-domain spectroscopy monitoring system uses a wavelet signal processing method to decompose the signal, obtains approximate coefficients and detail coefficients after the signal decomposition, reconstructs and filters them, and then performs frequency domain deconvolution through a Hanning window function, thereby detecting the first data set associated with the evolution of crack parameters and stress states at the interface between the ceramic layer and the bonding layer during the thermal shock assessment process as the thermal shock assessment cycle is executed.

7. The method according to claim 1, It is characterized in that Generating the corresponding digital twin model of the thermal barrier coating further includes: The first data set is input into the thermal shock life simulation model to modify a first parameter set of the thermal shock life simulation model associated with the evolution of crack parameters and stress states.

8. The method according to claim 7, It is characterized in that The digital twin model includes one or more of a thermal-mechanical coupling analysis model, a stress field analysis model, and a structural damage evolution model.

9. The method according to claim 1, It is characterized in that Updating the digital twin model based on the second data set includes: The actually measured second data set is input into the digital twin model to update a second parameter set of the digital twin model associated with the physical feature.

10. The method according to claim 9, It is characterized in that The evolution of the physical characteristics of the thermal barrier coating includes the evolution of microstructure, mechanical properties, damage state, and further includes one or more of the following: During the thermal shock process, the porosity of the ceramic layer evolves, the hardness, elastic modulus, and fracture toughness of the ceramic layer evolve, the crack length in the ceramic layer evolves, and the spalling area in the ceramic coating evolves.

11. A device for predicting the thermal shock life of a thermal barrier coating based on digital twins, comprising a processor and a memory, wherein the memory stores program instructions; the processor executes the program instructions to implement a method as claimed in any one of claims 1 to 10.

12. A non-transitory computer-readable storage medium storing instructions which, when executed by a computer, The computer is caused to execute the method for predicting the thermal shock life of a thermal barrier coating based on digital twins according to any one of claims 1 to 10.

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