Thermo-Mechanical Simulation of Residual Stresses in Plasma Sprayed Coatings
2018
Oukach, S. | Hamdi, H. | El Ganaoui, M. | Pateyron, B.
Thermal sprayed coatings have a crucial role for protection of surfaces against high temperature, wear, erosion and corrosion. They are built up by successive accumulation of thin layers, called splats, generated by impact and solidification of individual molten particles. However, the coatings properties such as adhesion strength and adherence to the substrate are strongly influenced by the presence of micro-cracks or interfacial debonding resulting from the relaxation of stresses generated within the coating. In this paper, a numerical simulation based on the Finite Element Method is carried out to analyze in a first time the thermo-mechanical process of the formation of the first splat, initially molten ceramic particle, deposited onto a metallic substrate. In a second time, the obtained results are used as initial conditions to predict the residual stress induced during deposition of the splat. The effect of substrate initial temperature on the stress generation is also analyzed and the results show that the residual stress can significantly be reduced when the substrate is preheated.
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