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There is described a method of modeling by the finite element method the residual stresses induced during thermal deposition of coatings. The simulation was performed in two stages. The first dynamic stage simulated the impacts of the individual particles of the coating material onto the substrate, and the next static stage included a non-linear thermo-mechanical analysis intended for simulating the process of layer-by-layer deposition of the coating, with a specified thickness, and then cooling the entire system to the ambient temperature. In the computations, the samples were assumed to be cylindrical in shape and composed of an Al2O3 substrate and a titanium coating (with three different thicknesses) deposited using the detonation method. The correctness of the numerical model was verified experimentally by measuring the deflections of a real Ti coating/Al2O3 substrate sample with the Ti coating detonation-sprayed on the ceramic substrate, after cooling it to the ambient temperature. The experimental results appeared to be in good agreement with those obtained by the numerical computations.
Słowa kluczowe
Rocznik
Tom
Strony
515--525
Opis fizyczny
Bibliogr. 30 poz., rys., tab., il., wykr.
Twórcy
autor
- Institute of Mechanics and Printing, Warsaw University of Technology, 85 Narbutta St., 02-524 Warsaw, Poland
autor
- Institute of Mechanics and Printing, Warsaw University of Technology, 85 Narbutta St., 02-524 Warsaw, Poland
autor
- Institute of Manufacturing Processes, Department of Welding Engineering, Warsaw University of Technology, 85 Narbutta St., 02-524 Warsaw, Poland
autor
- Institute of Manufacturing Processes, Department of Welding Engineering, Warsaw University of Technology, 85 Narbutta St., 02-524 Warsaw, Poland
autor
- Institute of Fluid-Flow Machinery, Polish Academy of Sciences, 1 Defilad Sq., 00-901 Warszawa, Poland
Bibliografia
- [1] Z. Gan and H.W. Ng, “Deposition-inducted residual stress in plasma-sprayed coatings”, Surface and Coating Technology 187, 307-319 (2004).
- [2] J. Stokes and L. Looney, “Residual stress in HVOF thermally sprayed thick deposits”, ICMCTF 1, CD-ROM (2003).
- [3] M. Li, P. Christofides, “Multi-scale modelling and analysis of an industrial hvof thermal spray process”, Chem. Eng. Sci. 60, 3649-3669 (2005).
- [4] N.J. Madejski, “Solidification of droplets on a cold surface”, Int. J. Heat Mass Transfer 19, 1009-1013 (1976).
- [5] M. Chmielewski and W. Weglewski, “Comparison of experimental and modelling results of thermal properties in Cu-AlN composite materials”, Bull. Pol. Ac.: Tech. 61 (2), 507-514 (2013).
- [6] K. Dems and Z. Mroz, “Analysis and design of thermomechanical interfaces”, Bull. Pol. Ac.: Tech., 60 (2), 205-213 (2012).
- [7] K. Pietrzak, D. Kaliński, and M. Chmielewski, “Interlayer of Al2O3-Cr functionally graded material for reduction of thermal stresses in alumina - heat resisting steel joints”, J. Eur. Ceramic Society 27 (2-3), 1281-1286 (2007).
- [8] W.G. Mao and Y.C. Zhou, “Failure of thermal barrier ceramic coating induced by buckling due to temperature gradient and creep”, Advanced Materials Research 9, 31-40 (2005).
- [9] W. Wlosinski and T. Chmielewski, “Plasma-hardfaced chromium protective coatings-effect of ceramic reinforcement on their wettability by glass”, Proc. 3rd Int. Conf. Surface Engineering 1, 48-53 (2002).
- [10] A.N. Khan, J. Lu, and H. Liao, “Effect of residual stresses on air plasma sprayed thermal barrier coatings”, Surface andCoatings Technology 168, 291-299 (2003).
- [11] W. Węglewski, M. Basista, M. Chmielewski, and K. Pietrzak, “Modelling of thermally induced damage in the processing of Cr-Al2O3 composites”, Composites Part B 43 (2), 255-264 (2012).
- [12] Y.C. Tsui and T.W. Clyne, “An analytical model for predicting residual stresses in progressively deposited coatings. Part 1: Planar geometry”, Thin Solid Films 306, 23-33 (1997).
- [13] A. Mezin, “Coating internal stress measurement through the curvature method: A geometry-based criterion delimiting the relevance of Stoney’s formula”, Surface and Coatings Technology 200, 5259-5267 (2006).
- [14] X. Feng, Y. Huang, and A.J. Rosakis, “On the Stoney formula for a thin film/substrate system with nonuniform substrate thickness”, Trans. ASME 74, 1276-1281 (2007).
- [15] D. Golański, T. Wierzchoń, and P. Biliński, “Numerical modelling of the residual stresses in borided layers on steel substrate”, J. Materials Science Letters 14, 1499-1501 (1995).
- [16] M. Toparlia, F. Sen, O. Culha, and E. Celik, “Thermal stress analysis of HVOF sprayed WC-Co/NiAl multilayer coatings on stainless steel substrate using ?nite element methods”, J.Materials Processing Technology 190, 26-32 (2007).
- [17] T. Chmielewski and D. Golański, “Selected properties of Ti coatings deposited on ceramic AlN substrates by thermal spraying”, Welding Int. 1, 1-6 (2011).
- [18] X.C. Zhang, B.S. Xu, H.D. Wang, and Y.X. Wu, “Modeling of the residual stresses in plasma-spraying functionally graded ZrO2/NiCoCrAlY coatings using ?nite element method”, Materials and Design 27, 308-315 (2006).
- [19] P. Bengtsson and C. Persson, “Modelled and measured residual stresses in plasma sprayed thermal barrier coatings”, Surfaceand Coatings Technology 92, 78-86 (1997).
- [20] R. Ghafouri-Azar, J. Mostaghimi, and S. Chandra, “Modeling development of residual stresses in thermal spray coatings”, Computational Material Science 35, 13-26 (2006).
- [21] X. Zhang, J. Gong, and S. Tu, “Effect of spraying condition and material properties on the residual stress in plasma spraying”, J. Material Science Technology 20 (2), 149-153 (2004).
- [22] S. Widjaja, A.M. Limarga, and T.H. Yip, “Modeling of residual stresses in a plasma-sprayed zirconia/alumina functionally graded-thermal barrier coating”, Thin Solid Films 434, 216-227 (2003).
- [23] K.-R. Donner, F. Gaertner, and T. Klassen, “Metallization of thin Al2O3 layers in power electronics using cold gas spraying”, J. Thermal Spray Technology 20 (1-2), 299-306 (2011).
- [24] T. Chmielewski, “Application of kinetic energy of friction and detonation wave for metallisation of ceramics”, Scientific Papersof Warsaw University of Technology. Mechanic Series 242, 1-157 (2012), (in Polish).
- [25] T. Watanabe, I. Kuribayashi, T. Honda, and A. Kanzawa, “Deformation and solidification of a droplet on a cold substrate”, Chem. Eng. Sci. 47, 3059-3065 (1992).
- [26] C.H. Amon, R. Merz, F.B. Prinz, and K.S. Schmaltz, “Numerical and experimental investigation of interface bonding via substrate melting of an impinging molten metal droplet”, J. Heat Transfer 118, 16-172 (1996).
- [27] G.R. Johnson and W.H. Cook, “A constitutive model and data for metals subjected to large strains, high strain rates, and high temperatures”, Proc. 7th Int. Symp. on ‘Ballistics’ 1, 541-547 (1983).
- [28] G.R. Johnson and T.J. Holmquist, “An improved computational constitutive model for brittle materials”, High-Pressure Scienceand Technology 309, 981-984 (1994).
- [29] R. Boyer, G. Welsch, and E. Collings, Materials PropertyHandbook: Titanium Alloys, ASM International, Materials Park, 1994.
- [30] A. Goldsmith, T.E. Waterman, and H.J. Hirchorn, “Handbookof Thermophysical Properties of Solid Materials”, Academic Press, New York, 1961.
Typ dokumentu
Bibliografia
Identyfikator YADDA
bwmeta1.element.baztech-e18bd4b2-14aa-43d0-887b-d2e8c7ede20d