For nickel-based single crystal superalloy DD6 (AECC Beijing Institute of Aeronautical Materials, Beijing, China) material, a method for predicting creep rupture time was proposed based on a newly defined equivalent stress method. An anisotropic creep model for describing the orientation-dependent creep behavior and lifetime of a nickel-based single crystal superalloy was proposed. The creep subroutine was written based on the proposed nickel-based single crystal creep model. The stability of the model was improved by adjusting the iterative algorithm. The creep calculation results in [001], [011], and [111] loading directions were compared with the experimental results. The accuracy of the calculation results by the nickel-based single crystal creep subroutine was verified. The initial time step and maximum time step of the creep subroutine were studied.

Creep tests were conducted on DZ411 material at 930 °C and 850 °C, and creep curves were recorded and employed in normalization creep model building. A yield function suitable for directional solidification nickel-based materials was proposed in an ascending-order approach. Combined with the normalized creep model and the proposed function, a creep subroutine was compiled to simulate the creep deformation behavior of a turbine blade. The typical boundary conditions of the blade were determined and used for finite element analysis. According to the analysis results, the assessment positions for the actual application of a turbine blade were determined and checked for endurance intensity. The phenomenon of deviation angle between crystal axis and blade height direction in actual casting was further analyzed. Multiple angles and directional deviation angles were simulated for 10,000 h creep deformation. Considering the difficulties and challenges of the complex geometric structures of blades, it is necessary to conduct creep tests of DZ411 material and a simulation analysis of a real blade. Based on the above analysis and discussion, the present work sheds light on finite element analysis and has great potential for structural analyses in the engineering applications of complex high-temperature structures.

Interfacial stress between layers of thermal barrier coatings near free edges is a critical factor that may cause turbine blades to fail. This paper uses simulation methods to reveal the effects of variations in geometric and material parameters on the stress of thermal barrier coatings. The stress distributions of a disk-shaped coating–substrate system undergoing thermal mismatch are calculated by an analytical method and the finite element method. The analytical solution reveals that the coefficient of thermal expansion, elasticity modulus, Poisson’s ratio, and thickness of each layer affect interfacial stress between coatings and substrate. The simulation results exhibit significant concentrations of the normal and shear stresses, which make the coating system prone to cracking and spalling from the free edge. The parametric analysis highlights that the thermal mismatch strain affects the stress magnitude. The region affected by free edges becomes larger with increasing thickness, elasticity modulus, and Poisson’s ratio of the topcoat. Finally, two integral parameters are proposed to represent the stress state near the free edge related to mode I and II fracture, respectively. The parameters, not sensitive to the grid density, are validated by experiments.

In order to investigate the influence of notched structures on creep performance under long-term high-temperature conditions, durability tests were conducted on ring-notched and hole-containing thin tubular specimens of directional columnar-grain DZ411 alloy at 850 °C and 930 °C. The results were compared with those of smooth round rod specimens at same temperatures and stress levels, to evaluate the impact of notched structures described above on the rupture life. Based on the experimental data, a finite element subroutine was developed using a macroscopic phenomenological creep model to simulate the creep deformation behavior of the structural components. The stress relaxation characteristics of the two types of notched structures were analyzed. The results show that the ring-notched structure exhibits significant stress relaxation, leading to a “notch strengthening” effect, which improves the endurance property; conversely, the small-hole structure shows insufficient stress relaxation, resulting in “notch weakening” and a reduction in the endurance property. The developed subroutine demonstrates sufficient engineering accuracy in notch creep simulation. Using creep strain as the fracture criterion, the predicted endurance life showed a deviation from experimental results within the acceptable engineering range, indicating that the subroutine has sufficient engineering accuracy.