Residual Stresses in Thermal Spray Coatings and Their Effect on Interfacial Adhesion: A Review of Recent Work

1996 ◽  
Vol 5 (4) ◽  
pp. 401-418 ◽  
Author(s):  
T. W. Clyne ◽  
S. C. Gill
Keyword(s):  
Residual Stresses ◽  
Recent Work ◽  
Thermal Spray ◽  
Interfacial Adhesion ◽  
Thermal Spray Coatings ◽  
Spray Coatings

Methods of Determination and Control of Residual Stresses in Plasma Spray Coatings

1997 ◽  
Author(s):  
L. Dekhtyar ◽  
A. Kleyman ◽  
V. Andreychuk ◽  
S. Berman
Keyword(s):  
Residual Stresses ◽  
Thermal Spray ◽  
Plasma Spray ◽  
Thermal Spraying ◽  
Thermal Spray Coatings ◽  
Coating Deposition ◽  
Spray Coatings ◽  
Plasma Spray Coatings ◽  
And Control ◽  
Elastic Characteristics

Abstract Residual stresses exert profound influence on the longevity of parts with thermal spray coatings. The distribution and value of the residual stresses depend on method of coating deposition, composition of the applied material, parameters of thermal spraying and methods of post-treatment. Therefore, the study of the influence of the various technological factors on the residual stresses in the plasma spray coatings is very important. Due to heterogeneity of the coating, residual stresses can be determined only by the experimentation by using new methods which take into consideration real values of elastic characteristics and density of elementary layers. Methods and formulas for the calculations of the residual stresses in coatings deposited on bars, rings, discs, cylinders are presented. Experimental results for the various thermal spray coatings are also shown. These results can be used for the optimization of coating deposition and would supplement the existing database.

scholarly journals Residual stresses in different thermal spray coatings

2002 ◽  
Vol 8 (3) ◽  
pp. 162
Author(s):  
J Kõo ◽  
P Kulu ◽  
H Lille ◽  
T Pihl
Keyword(s):  
Residual Stresses ◽  
Thermal Spray ◽  
Thermal Spray Coatings ◽  
Spray Coatings

An ASM Recommended Practice for Modified Layer Removal Method (MLRM) to Evaluate Residual Stress in Thermal Spray Coatings

2000 ◽  
Author(s):  
E.F. Rybicki ◽  
J.R. Shadley ◽  
R.T.R. McGrann ◽  
A.C. Savarimuthu ◽  
D. Graving
Keyword(s):  
Mechanical Properties ◽  
Residual Stress ◽  
Residual Stresses ◽  
Thermal Spray ◽  
Thermal Spray Coatings ◽  
Removal Method ◽  
Layer Removal ◽  
Spray Coatings ◽  
Layer Removal Method ◽  
Modified Layer

Abstract Thermal spray coatings are subjected to mechanical loadings in many applications, and there is a need to evaluate the mechanical properties of these coatings. Mechanical properties of interest in the performance of thermal spray coatings include fatigue life, wear resistance, bond strength. Young's modulus, Poisson's ratio, and residual stresses. One property that has a large effect on the performance of thermal spray coated parts is the residual stress distribution in the thermal spray coating and in the substrate. Thus, it is important to have (1) a fundamentally sound method for evaluating residual stresses and (2) a written recommended procedure for applying the method. ASM International is not a standard writing organization. Yet, the increased use of thermal spray coatings and the need for documentation on methods for evaluating mechanical properties of thermal spray coatings have generated a need to prepare Recommended Practices. To meet this need, the ASM International Thermal Spray Society has formed three subcommittees to prepare Recommended Practices for thermal spray coatings. This paper describes a draft form of a Recommended Practice for evaluating residual stresses in thermal spray coatings. This Recommended Practice is being developed by the Subcommittee on "Evaluating of Mechanical Properties of Thermal Spray Coatings". The method, called the Modified Layer Removal Method, has been presented in several papers and has been used for a variety of different coatings. The paper describes the dimensions of the test specimen, the equipment needed, the procedure for removing layers, and the methods for collecting and interpreting the data to evaluate through thickness residual stresses. The Recommended Practice (RP) is in Draft form, but is presented to let the thermal spray community know about the RP effort and invite comments and volunteers to write other RP's.

Micro and Macroscopic Approaches to Residual Stress Generation Mechanism of Thermal Spray Coatings

2000 ◽  
Author(s):  
S. Tobe ◽  
Y. Andou ◽  
M. Ando ◽  
S. Kuroda ◽  
K. Akita
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Thermal Spray ◽  
Stress Measurement ◽  
Coefficient Of Thermal Expansion ◽  
Steel Substrate ◽  
Generation Mechanism ◽  
Thermal Spray Coatings ◽  
Stress Generation ◽  
Spray Coatings

Abstract Microscopic and macroscopic residual stress measurements and a finite element method (FEM) for stress analysis of thermal spray coatings have been carried out to investigate the residual stress generation mechanism. The residual stresses of one splat, laminated two splats and coatings were measured by a micro-beam x-ray stress measurement system and the macroscopic residual stresses were measured in-situ by the curvature change of the thin substrate plate during and after spraying. Two coating materials were employed in this study to deposit the coatings. One is molybdenum of which the coefficient of thermal expansion (CTE) is smaller than that of steel substrate and the other is 80%Ni-20%Cr alloy which has higher CTE than steel. The substrate was preheated up to 550°C just before spraying. The residual stresses of the splat and a coating are fundamentally the same level. The FEM analysis on the residual stress was also useful and by the comparison of two measurement results of microscopic and macroscopic residual stresses, the generation mechanism was discussed.

Modeling development of residual stresses in thermal spray coatings

2006 ◽  
Vol 35 (1) ◽  
pp. 13-26 ◽  
Author(s):  
R. Ghafouri-Azar ◽  
J. Mostaghimi ◽  
S. Chandra
Keyword(s):  
Residual Stresses ◽  
Thermal Spray ◽  
Thermal Spray Coatings ◽  
Spray Coatings

Effect of heat transfer on residual stresses in thermal spray coatings

2019 ◽  
Vol 33 (5) ◽  
pp. 493-510
Author(s):  
Zhidan Zhou ◽  
Yongxiong Chen ◽  
Xiubing Liang ◽  
Baolong Shen ◽  
Dashu Guan
Keyword(s):  
Heat Transfer ◽  
Residual Stresses ◽  
Thermal Spray ◽  
Thermal Spray Coatings ◽  
Spray Coatings

Residual stresses and adhesion of thermal spray coatings

2005 ◽  
Vol 21 (1) ◽  
pp. 35-40 ◽  
Author(s):  
P. Araujo ◽  
D. Chicot ◽  
M. Staia ◽  
J. Lesage
Keyword(s):  
Residual Stresses ◽  
Thermal Spray ◽  
Thermal Spray Coatings ◽  
Spray Coatings

scholarly journals Sliding Wear of Conventional and Suspension Sprayed Nanocomposite WC-Co Coatings: An Invited Review

2021 ◽  
Author(s):  
R. Ahmed ◽  
O. Ali ◽  
C. C. Berndt ◽  
A. Fardan
Keyword(s):  
Wear Rate ◽  
Thermal Spray ◽  
Sliding Wear ◽  
Failure Modes ◽  
Thermal Spray Coatings ◽  
Annual Growth Rate ◽  
Total Energy Consumption ◽  
Wear Performance ◽  
Wear Rates ◽  
Spray Coatings

AbstractThe global thermal spray coatings market was valued at USD 10.1 billion in 2019 and is expected to grow at a compound annual growth rate of 3.9% from 2020 to 2027. Carbide coatings form an essential segment of this market and provide cost-effective and environmental friendly tribological solutions for applications in aerospace, industrial gas turbine, automotive, printing, oil and gas, steel, and pulp and paper industries. Almost 23% of the world’s total energy consumption originates from tribological contacts. Thermal spray WC-Co coatings provide excellent wear resistance for industrial applications in sliding and rolling contacts. Some of these applications in abrasive, sliding and erosive conditions include sink rolls in zinc pots, conveyor screws, pump housings, impeller shafts, aircraft flap tracks, cam followers and expansion joints. These coatings are considered as a replacement of the hazardous chrome plating for tribological applications. The microstructure of thermal spray coatings is however complex, and the wear mechanisms and wear rates vary significantly when compared to cemented WC-Co carbides or vapour deposition WC coatings. This paper provides an expert review of the tribological considerations that dictate the sliding wear performance of thermal spray WC-Co coatings. Structure–property relationships and failure modes are discussed to grasp the design aspects of WC-Co coatings for tribological applications. Recent developments of suspension sprayed nanocomposite coatings are compared with conventional coatings in terms of performance and failure mechanisms. The dependency of coating microstructure, binder material, carbide size, fracture toughness, post-treatment and hardness on sliding wear performance and test methodology is discussed. Semiempirical mathematical models of wear rate related to the influence of tribological test conditions and coating characteristics are analysed for sliding contacts. Finally, advances for numerical modelling of sliding wear rate are discussed.

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