Abstract
Thermal stresses arise during the thermal plasma spraying of composite coatings, influenced by the differing thermophysical properties of the substrate and coating materials. This study focuses on a thick coating with a top NiTi layer and a base stainless steel (AISI 304) substrate, along with an epoxy carrier layer. Initially, the substrate is stress-free at the deposition temperature of 1400 °C. Once the coating is applied, the carrier layer activates at 150°C, introducing thermal stresses before cooling to room temperature (20 °C). Using COMSOL Multiphysics, we examine stress distribution within the assembly at both 150 °C and room temperature. The model treats the thick plate as a two-dimensional solid, with layers assumed to be isotropic and linear elastic. The higher coefficient of thermal expansion in the substrate (17.3 × 10⁻⁶) compared to the coating (11 × 10⁻⁶) results in tensile stresses in the substrate and compressive stresses in the coating.
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