Modeling stress evolution in porous ceramics subjected to molten silicate infiltration and corrosion

•A model of corrosion failure in porous ceramics is proposed.•The coupled effects of infiltration, corrosion, and deformation are considered.•The corrosion process and delamination mechanism of TBCs are successfully predicted.•Cracks tend to initiate from the side edges of TBCs columns at the infiltration interface. Corrosion failure leads to huge economic losses and potential safety issues in many fields. With a focus on corrosion failure in porous ceramics infiltrated by molten silicates, we developed a mechanical model based on thermodynamic laws that considers infiltration, diffusion, corrosion, and deformation. The model was used to analyze the failure mechanism of thermal barrier coatings (TBCs) corroded by molten silicates. The modeled corrosion process was consistent with experimental results. The delamination mechanism of TBCs due to corrosion was successfully revealed. The model has great potential in analyzing corrosion failure in porous ceramics.