Residual Stress in High-Velocity Impact Coatings: Parametric Finite Element Analysis Approach
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Residual Stress in High-Velocity Impact Coatings: Parametric Finite Element Analysis Approach Felipe Oviedo1 • Alfredo Valarezo1
Submitted: 13 November 2019 / in revised form: 11 March 2020 ASM International 2020
Abstract High-velocity impact coatings are produced by techniques such as HVOF, HVAF, cold spraying, warm spraying, and supersonic plasma spraying. All these processes have in common the impact of particles at high velocities that produce peening of the surface and induce compressive residual stresses in the radial and axial orientations of the impact. If the process involves a significant heat input to the particles, quenching of splats and thermal mismatch between coating and substrate adds residual stress to the peening, and subsequently defines the final stress state. Through a parametric finite element model of coating formation, physical variables—including particle temperature and velocity, particle mass, particle morphology and deposition temperature—are studied to observe their effect on residual stresses, and define their possible manipulation to design coatings of desired average residual stress. To allow key parameter selection, a contour map of SS316 feedstock deposited on SS316 substrate is produced based on the parametric modeling of particle impact (via an explicit FE model) and the subsequent layer-by-layer coating formation (via an implicit FE model) employing ABAQUS code. The Johnson–Cook model for high 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. & Alfredo Valarezo [email protected] 1
IIMA-Institute of Materials Research, Mechanical Engineering Department, Universidad San Francisco de Quito, Av. Diego de Robles S/N y Pampite, Quito, Ecuador
strain, strain rate and temperature is used as the constitutive equation for the study of impact and rapid cooling. Keywords finite element analysis high-velocity impact coatings parametric analysis peening quenching residual stress
Introduction High-velocity (HV) spraying techniques are the preferred manufacturing processes for thick metal/alloy and hard cermet coatings. HV impact coating technologies include: high-velocity oxy-fuel (HVOF), high-velocity air–fuel (HVAF) spraying, cold gas spraying, warm spraying, supersonic plasma spraying, detonation spraying, etc. HV impact technologies are capable of producing dense structures at a high deposition rate relative to other surface technologies. However, some limitations of the process arise especially due to residual stresses. Some of these issues are limited coating thickness, premature delamination, cracking, etc. In all these techniques, the effects of particle impact and temperature gradients
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