Residual Stress Distribution Through the Thickness of WC-10Co-4Cr Coating Deposited by HVOF: Experimental and Simulation
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Residual Stress Distribution Through the Thickness of WC-10Co4Cr Coating Deposited by HVOF: Experimental and Simulation Study Maedeh Sadat Zoei1 • Tara Farizeh2 • Mohammad Hosein Sadeghi3 Mehdi Salehi4
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Submitted: 29 August 2019 / in revised form: 2 February 2020 Ó ASM International 2020
Abstract Utilization of WC-10Co-4Cr coating, sprayed by High-Velocity Oxygen Fuel, has significantly expanded due to its high corrosion and wear resistance. In this study, the in-plane residual stresses in the coating were determined experimentally with the x-ray diffraction technique, using the sin2 w method and compared to finite element analysis (FEA). The chemical layer removal process was used to determine the residual stress experimentally, through the thickness of the coating. In the FEA, the effect of impingement of a WC-10Co-4Cr particle on the substrate was first studied and the results of impingement analysis were used as input data in a thermomechanical model of the coating process. Experimental results, in agreement with simulation studies, showed that the inplane surface residual stresses in the WC-10Co-4Cr coating were compressive. The magnitude of this compressive
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. & Maedeh Sadat Zoei [email protected] 1
Institute of Materials and Energy, Iranian Space Research Center, Isfahan, Iran
2
Caspian Faculty of Engineering, College of Engineering, University of Tehran, Gilan, Iran
3
Department of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran
4
Department of Material Engineering, Isfahan University of Technology, Isfahan, Iran
stress increased with depth, relative to the free surface of the coating. The largest compressive residual stress was measured at the coating–substrate interface. Simulation results predicted that the stress distribution through the coating was uniform, except at the edges of the sample, where tensile stress concentrations existed at the coating– substrate interface. This region is thus prone to cracks and delamination of the coating. Keywords HVOF WC-10Co-4Cr coating Residual stress Finite element analysis
Introduction Thermal sprayed coatings, based on tungsten carbides, provide appropriate resistance against wear and corrosion (Ref 1). The High-Velocity Oxygen Fuel (HVOF) thermal spray process is one of the most important processes to deposit carbide coatings. HVOF carbide coatings have various advantages such as low porosity, high bond strength and high hardness, due to the elevated velocity of the particles during deposition (Ref 2, 3). WC-10Co-4Cr coatings produced by HVOF thermal spray process are one of the most widely used carbide c
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