A Stochastically Generated Geometrical Finite Element Model for Predicting the Residual Stresses of Thermally Sprayed Co
- PDF / 4,752,665 Bytes
- 12 Pages / 595.276 x 790.866 pts Page_size
- 62 Downloads / 213 Views
PEER REVIEWED
A Stochastically Generated Geometrical Finite Element Model for Predicting the Residual Stresses of Thermally Sprayed Coatings Under Different Process Parameters A. Gadelmoula1 • K. S. Al-Athel1 • S. S. Akhtar1 • A. F. M. Arif2
Submitted: 7 November 2019 / in revised form: 27 February 2020 ASM International 2020
Abstract In this work, a 3D stochastic model coupled with a finite element (FE) code is used to investigate the development of residual stresses in thermally sprayed coatings. The residual stresses of a thermally sprayed yttria-stabilized zirconia (YSZ) coating applied to stainless steel substrates are used for this work. The formation of the coating layers was simulated with a 3D stochastic model, SimCoat. Three YSZ coating models with a similar average thickness, but different layers (one-, two-, and three-layer coatings) were obtained by changing three process parameters: the material feed rate, the gun velocity, and the total number of passes. Two 2D slices of each 3D model were taken and converted into FE models using an in-house Python code. An FE simulation was then used to study the combined effect of these process parameters on the development of residual stresses. The variation of in-plane stresses through the thickness for each model was obtained, and a comparison between the developed stresses was conducted. The developed methodology was effective for understanding the effect of the coating process parameters on the development of residual stresses and can be used to This article is part of a special topical focus in the Journal of Thermal Spray Technology on Advanced Residual Stress Analysis in Thermal Spray and Cold Spray Processes. This issue was organized by Dr. Vladimir Luzin, Australian Centre for Neutron Scattering; Dr. Seiji Kuroda, National Institute of Materials Science; Dr. Shuo Yin, Trinity College Dublin; and Dr. Andrew Ang, Swinburne University of Technology. & K. S. Al-Athel [email protected] 1
Mechanical Engineering Department, King Fahd University of Petroleum & Minerals, Dhahran 31261, Saudi Arabia
2
Department of Mechanical Engineering, McMaster University, Hamilton, ON L8S 4L7, Canada
optimize the coating process parameters to obtain the desired residual stresses. Keywords coatings finite element residual stresses thermal spray YSZ
Introduction Ceramic coatings are widely used as a protective thin layer for metallic components that operate under severe conditions. Ceramic materials such as zirconia, silicon carbide, and silicon nitride are commonly used to provide thermal insulation to hot components to improve thermal efficiency and increase the component’s service life. Diesel engines and gas turbine blades are mostly coated by thermal barrier coatings developed by thermal spraying techniques (Ref 1-3). Thermal spraying is considered an economical and effective way of producing ceramic coatings on metallic substrates. In this process, the coating material, which is fed to the thermal spray system in the form of powder, is heated above its m
Data Loading...
