Finite Element Simulation of Residual Stress Development in Thermally Sprayed Coatings
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Finite Element Simulation of Residual Stress Development in Thermally Sprayed Coatings Mohamed Elhoriny1,2 • Martin Wenzelburger1 • Andreas Killinger1 Rainer Gadow1
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Submitted: 15 February 2016 / in revised form: 6 February 2017 / Published online: 16 March 2017 ASM International 2017
Abstract The coating buildup process of Al2O3/TiO2 ceramic powder deposited on stainless-steel substrate by atmospheric plasma spraying has been simulated by creating thermomechanical finite element models that utilize element death and birth techniques in ANSYS commercial software and self-developed codes. The simulation process starts with side-by-side deposition of coarse subparts of the ceramic layer until the entire coating is created. Simultaneously, the heat flow into the material, thermal deformation, and initial quenching stress are computed. The aim is to be able to predict—for the considered spray powder and substrate material—the development of residual stresses and to assess the risk of coating failure. The model allows the prediction of the heat flow, temperature profile, and residual stress development over time and position in the coating and substrate. The proposed models were successfully run and the results compared with actual residual stresses measured by the hole drilling method. Keywords APS coating buildup FEA residual stress modeling
This article is an invited paper selected from presentations at the 2015 International Thermal Spray Conference, held May 11-14, 2015, in Long Beach, CA, USA, and has been expanded from the original presentation. & Mohamed Elhoriny [email protected] 1
Graduate School of Excellence Advanced Manufacturing Engineering (GSaME), Stuttgart University, Stuttgart, Germany
2
Institute for Manufacturing Technologies of Ceramic Components and Composites (IMTCCC), Stuttgart University, Stuttgart, Germany
Introduction Thermal spray technology is a major technique for application of functional coatings onto component surfaces, and great attention has been drawn to affordable optimization of spraying parameters to obtain stable and reproducible coatings with predefined dimensional tolerances and properties (Ref 1, 2). Many aspects of these processes have been thereby understood, and the fundamental relationships between the spraying parameters and the properties of the obtained coating have been determined for many coating-substrate material systems (Ref 3-6). In general, thermokinetic coating techniques use a particle-loaded hot gas jet to form metal, ceramic, or metal–ceramic functional coatings. The jet is guided by industrial robots so that prescribed coating patterns can be deposited with high dimensional accuracy on component surfaces. Due to the intensive heat exchange that occurs between the hot gas jet and substrate in this approach, besides deposition of molten or semimolten coating material, large heat transfer into the component also occurs. The resulting heat profiles, accompanied by the mismatch between the thermal properties of t
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