Thermal coupling field analysis of thermal barrier coating structure based on Green's function

Thermal Barrier Coatings (TBCs) are one of the core technologies that ensure the service of high-performance aero-engine turbine blades, rocket engines thrust chamber walls, and other advanced equipment in extreme high-temperature environments. However, accurately calculating the structural thermo-mechanical coupled field remains a core challenge due to the interface complexity and discontinuity in TBCs. To address the bottle-neck problems such as poor convergence and low efficiency existing in the analysis of interface discontinuous fields by traditional numerical methods, we propose a refined calculation method for the thermo-mechanical coupled field of TBC structures based on the Green's function theory. Utilizing the general solution of the material, a concise harmonic function containing undetermined constants is constructed and substituted into the general solution. The undetermined constants are determined by boundary conditions, interface conditions, and thermo-mechanical equilibrium conditions, yielding a comprehensive analytical solution for the thermo-elasticity of TBC structures. Based on the solution, the sensitivity analyses of parameters such as coating thick-ness and thermal expansion mismatch effect were systematically carried out, revealing the influence laws of coating thickness and thermal parameter mismatch on the interfacial stress field. This study provides a theoretical foundation for the precise design of TBC structures and for investigating interface failure mechanisms.