Data-Driven Thermo-Structural Optimization of Gas Turbine Blades Using Finite Element Modeling, Cooling Configurations, and Thermal Barrier Coatings

Gas turbine blades operate under extremely severe thermo-mechanical environments characterized by elevated turbine inlet temperatures, high centrifugal forces, thermal gradients, oxidation, and cyclic loading conditions. Continuous improvements in gas turbine efficiency have significantly increased turbine inlet temperatures beyond the thermal capability of conventional metallic materials, thereby necessitating the development of advanced cooling strategies and thermal protection systems. Among the available cooling approaches, film cooling combined with Thermal Barrier Coatings (TBCs) has emerged as one of the most effective techniques for reducing blade surface temperature and improving operational durability. However, the simultaneous interaction between cooling-hole configuration, material selection, thermal resistance, and coating-induced stresses introduces complex thermo-structural challenges that require detailed numerical investigation. Existing studies primarily focus on isolated thermal or structural analyses, while limited research has integrated data-driven thermo-structural optimization with comparative evaluation of cooling configurations and coating systems under realistic operating conditions. The present study investigates the thermo-structural performance of gas turbine blades using finite element analysis (FEA) under different cooling configurations and material selections. Three substrate materials, namely Inconel 718, N-155 alloy, and Chromium Steel, were analysed using ANSYS Workbench under steady-state thermal and structural loading conditions. Film cooling was modelled using 5-hole, 9-hole, and 13-hole radial cooling configurations. Furthermore, a two-layer Thermal Barrier Coating system consisting of a 250 μm Yttria-Stabilized Zirconia (YSZ) top coat and a 100 μm MCrAlY bond coat was incorporated to evaluate coating effectiveness and interfacial stress behaviour. Thermo-fluid calculations, stress analysis, and heat-transfer modelling were coupled with statistical interpretation of simulation outputs to establish a data-driven optimization framework for turbine blade cooling performance. The results indicate that Inconel 718 exhibits superior thermal resistance and structural stability compared to N-155 and Chromium Steel. The 5-hole cooling configuration demonstrated the lowest heat flux values, indicating optimum cooling effectiveness before the onset of diminishing thermal returns associated with excessive cooling-hole density. The incorporation of TBC layers reduced substrate temperature significantly while simultaneously introducing localized interfacial stresses due to thermal expansion mismatch. Comparative analysis revealed that the combined application of Inconel 718 substrate material, optimized film cooling, and ceramic TBC protection provides enhanced thermal protection, reduced deformation, lower von Mises stress, and improved service life for high-temperature turbine applications. The proposed data-driven thermo-structural optimization framework provides valuable engineering insights for the design of next-generation gas turbine cooling systems and advanced thermal management strategies.