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Modeling development of residual stresses in thermal spray coatings

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Title: Modeling development of residual stresses in thermal spray coatings
Authors: Ghafouri-Azar, R.1, Mostaghimi, J. mostag@mie.utoronto.ca, Chandra, S.1
Source: Computational Materials Science. Jan2006, Vol. 35 Issue 1, p13-26. 14p.
Subjects: Residual stresses, Coating processes, Strains & stresses (Mechanics), Surfaces (Technology)
Abstract: Abstract: The diameter, velocity and temperature of stainless steel and tungsten carbide cobalt particles applied onto stainless steel substrates using a high velocity oxy-fuel (HVOF) torch were measured. The microstructure of the coatings produced was examined using a scanning electron microscope and coating thickness, porosity and roughness measured. Using the experimental spray parameters as inputs to a 3-D stochastic model we simulated coating formation. Measured values of coating thickness and porosity agreed well with predicted values while calculated surface roughness was somewhat higher than that observed in experiments. An object oriented finite element code (OOF) developed at the National Institute of Standards and Technology was used to calculate residual stresses in the coating. The model uses an adaptive meshing technique to discretize the coating microstructure into a mesh suitable for finite element analysis. To define the coating geometry we used either micrographs of coating cross-sections or computer generated images of coatings. Similar values of residual stress are obtained in either case. High stresses are present at the interface between the coating and substrate. The magnitude of stresses increases significantly with coating thickness. Stresses are relieved by voids such as pores or cracks in the coating. Residual stresses increase with coating temperature and can be decreased by preheating the substrate. [Copyright &y& Elsevier]
Copyright of Computational Materials Science is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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Header DbId: egs
DbLabel: Engineering Source
An: 18342716
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
PreciseRelevancyScore: 0
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  Data: Modeling development of residual stresses in thermal spray coatings
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  Data: <searchLink fieldCode="AR" term="%22Ghafouri-Azar%2C+R%2E%22">Ghafouri-Azar, R.</searchLink><relatesTo>1</relatesTo><br /><searchLink fieldCode="AR" term="%22Mostaghimi%2C+J%2E%22">Mostaghimi, J.</searchLink><i> mostag@mie.utoronto.ca</i><br /><searchLink fieldCode="AR" term="%22Chandra%2C+S%2E%22">Chandra, S.</searchLink><relatesTo>1</relatesTo>
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  Data: <searchLink fieldCode="JN" term="%22Computational+Materials+Science%22">Computational Materials Science</searchLink>. Jan2006, Vol. 35 Issue 1, p13-26. 14p.
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  Data: <searchLink fieldCode="DE" term="%22Residual+stresses%22">Residual stresses</searchLink><br /><searchLink fieldCode="DE" term="%22Coating+processes%22">Coating processes</searchLink><br /><searchLink fieldCode="DE" term="%22Strains+%26+stresses+%28Mechanics%29%22">Strains & stresses (Mechanics)</searchLink><br /><searchLink fieldCode="DE" term="%22Surfaces+%28Technology%29%22">Surfaces (Technology)</searchLink>
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  Label: Abstract
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  Data: Abstract: The diameter, velocity and temperature of stainless steel and tungsten carbide cobalt particles applied onto stainless steel substrates using a high velocity oxy-fuel (HVOF) torch were measured. The microstructure of the coatings produced was examined using a scanning electron microscope and coating thickness, porosity and roughness measured. Using the experimental spray parameters as inputs to a 3-D stochastic model we simulated coating formation. Measured values of coating thickness and porosity agreed well with predicted values while calculated surface roughness was somewhat higher than that observed in experiments. An object oriented finite element code (OOF) developed at the National Institute of Standards and Technology was used to calculate residual stresses in the coating. The model uses an adaptive meshing technique to discretize the coating microstructure into a mesh suitable for finite element analysis. To define the coating geometry we used either micrographs of coating cross-sections or computer generated images of coatings. Similar values of residual stress are obtained in either case. High stresses are present at the interface between the coating and substrate. The magnitude of stresses increases significantly with coating thickness. Stresses are relieved by voids such as pores or cracks in the coating. Residual stresses increase with coating temperature and can be decreased by preheating the substrate. [Copyright &y& Elsevier]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Computational Materials Science is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1016/j.commatsci.2005.02.007
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        Text: English
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        Type: general
      – SubjectFull: Coating processes
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      – SubjectFull: Strains & stresses (Mechanics)
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      – SubjectFull: Surfaces (Technology)
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      – TitleFull: Modeling development of residual stresses in thermal spray coatings
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              Text: Jan2006
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