Abstract
This study is based on Eulerian method to model residual stresses for yttrium-stabilized zirconia coating applied to stainless steel substrate. A commercially available finite element software ABAQUS/Explicit is used to conduct this study. Single and multiple-particle impact analyses were carried out, and the residual stress data have been reported. The analysis is performed for two different values of thermal contact resistance and the through-thickness residual stress profiles obtained within the coating for single particle are tensile, while the substrate has a mixture of tensile and compressive residual stresses. For multiple impact model, the residual stress data have been presented for substrate with and without cooling. The residual stresses within the coating without substrate cooling are mostly tensile while the substrate is compressive. The residual stresses within the coating with substrate cooling are mostly tensile with compressive stresses on the top of the coating, while the substrate consists of compressive stresses. The obtained residual stresses are compared with experimental and analytical data.
Highlights
Thermal spray technology comprises a group of coating processes in which finely divided metallic or nonmetallic particles are deposited in molten or semi-molten condition to form a coating
The flattening degree obtained from the coupled Eulerian–Lagrangian method (CEL) and Eulerian model in this paper is found to be in close agreement with the experimental and numerical data
The flattening degree obtained from CEL has higher flattening degree at higher velocities, the data obtained from Eulerian model’s prediction of flattening degree are in better agreement with numerical data obtained by Zhu et al (Ref 58)
Summary
Thermal spray technology comprises a group of coating processes in which finely divided metallic or nonmetallic particles are deposited in molten or semi-molten condition to form a coating. The particle is heated up to or above its melting point and is made to impact the substrate at moderate velocity (100-300 m/s) (Ref 1). The invention of thermal spray credit goes to MU Schoop (1911), who received patents along with several collaborators to commercialize the process (Ref 1). Understanding of lamella bonding, formation of microstructural features and residual stresses in the finished parts are some of the technological challenges. This paper deals with the evolution of residual stresses of YSZ particle from the point of impact of lamella particle until it has cooled down as the building block of coating microstructure
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