A coupled multiphysics framework for swirl-induced particle deposition-penetration and its integrated aerothermal-structural effects on a film-cooled coated vane

Calcium-magnesium-alumino-silicate (CMAS) deposition and penetration degrade the aerothermal performance and structural durability of film-cooled turbine vanes with thermal barrier coatings (TBCs). Although prior research has examined CMAS under uniform flows, the coupled effects of swirl-enhanced deposition and penetration-induced thermo-mechanical damage are not well quantified. To address this, we developed a multiphysics framework integrating a CMAS deposition-penetration-failure model, dynamic mesh adaptation, and conjugate heat transfer to simulate interactions among swirl flow, particle transport, heat transfer, coating stress, and failure probability of TBCs. Results show that higher Sn elevates surface temperatures and pressure losses: as Sn increases from 0.2 to 1.0, average temperature rises from 1047.9 K to 1091.3 K on the pressure side and from 1087.2 K to 1113.8 K on the suction side, while pressure loss increases from 98.0 Pa to 155.0 Pa. Deposition concentrates on the pressure side, with added mass of 1.722 × 10−4 kg at Sn = 0.6 and 1.40 × 10−4 kg at Sn = 1.0, accelerating TGO growth by 0.19 and 0.094 µm, respectively. Swirl-driven deposition raises von Mises stress markedly: between Sn = 0.2 and 0.6, stress increases by 4.47 MPa in the top coat, 58.6 MPa in the TGO, and 69.6 MPa in the bond coat. Under different swirl numbers, the maximum oxidation failure probabilities were 1.52%, 1.8%, and 2.2%, respectively. This study tend to provide the integrated quantification of swirl-controlled CMAS deposition and its thermo-structural consequences in film-cooled TBCs, offering a predictive framework for failure probabilities assessment under CMAS deposition and penetration conditions.