Discrete 3D modeling of porous-cracked ceramic at the microstructure scale

Abstract

The porous-cracked microstructure of plasma sprayed ceramics coatings directly influences their macroscopic mechanical response. A 3D micromechanical model based on the discrete element method (DEM) is developed to reproduce their behavior. 3D observations are conducted with FIB-SEM nano-tomography and image analysis is used to extract and discretize the microstructure. A modeling strategy is developed to incorporate both pores and cracks into the model while preserving the computation performance. The lattice nature of DEM is used for the modeling of crack thickness that are smaller than the discrete element size. A method to compute the crack thickness from gray level images is proposed. Virtual quasi-static tests are performed on a sample of yttria-stabilized-zirconia. The results are in accordance with the literature data, such as the anisotropy and the non-linear behavior. The model is helpful to precisely investigate the role of the microscopic components, and micro-cracking on the macroscopic failure.