Numerical evaluation of interface morphology and deposition temperature effects on stress distribution and coating failure in Cr2AlC-coated zirconium

This study presents a finite element simulation approach using submodels to evaluate the effects of interface morphology and high-power pulsed magnetron sputtering (HPPMS) deposition temperature on stress distribution and coating failure in Cr 2 AlC-coated zirconium, which is designed as the cladding tube system for nuclear power plants. For the numerical simulations, different interface morphologies of the coating system are constructed using the Gaussian distribution method. It ensures a close match between the simulations and experiments. Comparative analysis shows that rougher interfaces result in more significant stress concentrations after cooling due to mismatches between dimensions, shapes, and thermal properties. Under subsequent external loading, samples that undergo cooling fail earlier than those without experiencing cooling. In addition, for the same interface morphology, residual stress increases significantly at higher deposition temperatures, while fracture strain decreases slightly over the temperature range investigated. These findings provide a multi-scale investigation of Cr 2 AlC-coated zirconium systems and offer valuable insights for optimizing the coating process. By controlling substrate roughness and deposition temperature, the performance and adhesion of coated specimens can be effectively balanced. The reconstructed interface morphologies closely approximate realistic conditions, allowing standardized evaluation. The proposed method is accessible, reliable, and adaptable to various materials and coating systems.