Residual Thermal Stresses in a Fe3Al/Al2O3 Gradient Coating System

2008 ◽  
Vol 32 ◽  
pp. 71-74
Author(s):  
Jiang Ting Wang ◽  
Peter D. Hodgson ◽  
Jing De Zhang ◽  
Chun Hui Yang
Keyword(s):  
Plasma Spray ◽  
Thermal Stresses ◽  
Steel Substrate ◽  
Temperature Fields ◽  
Dominant Factor ◽  
Alumina Coating ◽  
Shear Stresses ◽  
Thermal Expansion Coefficients ◽  
Gradient Coating ◽  
Gradient Coatings

To combine the merits of both metals and ceramics into one material, many researchers have been studying the deposition of alumina coating using plasma spray on metal substrates. However, as the coatings are deposited at a high temperature, residual thermal stresses develop due to the mismatch of thermal expansion coefficients of the coating and substrate and these are responsible for the initiation and expansion of cracks, which induce the possible failure of the entire material. In this paper, the residual thermal-structural analysis of a Fe3Al/Al2O3 gradient coating on carbon steel substrate is performed using finite element modelling to simulate the plasma spray. The residual thermal stress fields are obtained and analyzed on the basis of temperature fields in gradient coatings during fabrication. The distribution of residual thermal stresses including radial, axial and shear stresses shows stress concentration at the interface between the coatings and substrate. The mismatch between steel substrate and composite coating is still the dominant factor for the residual stresses.

Optimization of CrN/CrCN Gradient Coatings

2015 ◽  
Vol 237 ◽  
pp. 41-46
Author(s):  
Łukasz Szparaga ◽  
Przemysław Bartosik ◽  
Adam Gilewicz ◽  
Jerzy Ratajski
Keyword(s):  
Steel Substrate ◽  
Optimization Procedure ◽  
Stress And Strain ◽  
Pareto Optimal ◽  
Optimal Solutions ◽  
Decision Criteria ◽  
Transition Functions ◽  
Gradient Coating ◽  
Decision Variables ◽  
Gradient Coatings

The paper describes the optimization procedure supporting the designing process of geometry of gradient coatings basing on numerical simulation of internal stress and strain distributions in the coating and substrate. In mathematical model the gradient coating is represented by the so-called transition functions describing the change of physico-chemical parameters such as Young's modulus, Poisson's ratio, thermal expansion coefficient and the density as a function of the spatial variables. The object of optimization is system composed of a CrN/CrCN gradient coating and Cr interlayer between the CrN /CrCN coating and the steel substrate deposited on nitrided 4140 steel substrate. Decision variables are: the parameters of the of curvature of transition function , thickness of gradient coating and the thickness of the Cr interlayer. Optimization was carried out under pre-defined fixed continuous external loads and created decision criteria were the functions of the state of stress and strain in the coating and the substrate. Using the optimization procedure the sets of optimal parameters (Pareto sets) of the PVD gradient coating/nitrided substrate systems, due to the adopted decision criteria were determined. The analysis of the obtained optimal solutions (Pareto-optimal sets) was carried out using the "utopian solution method". It was also examined the technological stability of the Pareto-optimal solutions (nondominated) by analyzing the number of direct neighbors of these solutions in the decision variables space.

Study of residual thermal stresses in hard-alloy coatings obtained by electropulse technology

2018 ◽  
Vol 84 (11) ◽  
pp. 42-45
Author(s):  
S. V. Novikov ◽  
A. V. Smirnov ◽  
M. G. Isayenkova ◽  
N. S. Ermakova
Keyword(s):  
Hard Alloy ◽  
Thermal Stresses ◽  
Steel Substrate ◽  
Alloy Coating ◽  
External Pressure ◽  
Temperature Fields ◽  
Coating Application ◽  
Heat Penetration ◽  
Thermal Influence ◽  
The Impact

Qualitative and quantitative estimates of the temperature fields and level of the residual thermal stresses (RTS) in a steel substrate and hard-alloy coating obtained by electropulse technology (EPT) are presented. The estimation was carried out using the finite element method (FEM) and universal COMSOL Multiphysics® software to simulate applied problems. The results of the simulation showed that the higher the rate of mechanical loading, the smaller the depth of heat penetration into the substrate, the residual thermal stresses being localized in the zone of thermal influence near the interaction surface. At the same time, a thin layer of steel cannot cause considerable stresses in the bulk of the hard alloy. The stresses in the steel layer reach the yield point and the layer deforms without formation of large tensile stresses in the hard alloy. A criterion has been obtained that makes it possible to reveal the range of coating application parameters in which the impact of the steel substrate on the formation of residual thermal macro-stresses in the bulk of the hard-alloy coating is minimum. Electropulse equipment has been developed for application of the hard alloy coatings. Standard x-ray sin2Ψ-method (rotation method) is used for experimental evaluation of the macrostresses in the zone of the steel contact with the coating. Studies have shown that both radial and axial stresses are compressive; the maximum absolute values of the stress are observed in the radial direction in the outer layers of the coating, while the axial stresses relax near the free surface. Radial stresses in the outer layers of the coating reach a value of -210 MPa, and axial -110 MPa. The stresses in the coating layers contacting with steel are also characterized by rather high values, of the order of -160 ... -170 MPa. A high level of stress is attributed to the fact that the coating is formed under external pressure. At the same time the compressive stresses are favorable for a hard alloy, since it exhibits high values of the ultimate compression strength.

Analysis and Simulation of Thermal Transients and Resultant Stresses and Strains in TAB Packaging

1993 ◽  
Vol 115 (1) ◽  
pp. 34-38 ◽  
Author(s):  
M. A. Jog ◽  
I. M. Cohen ◽  
P. S. Ayyaswamy
Keyword(s):  
Thermal Stresses ◽  
Equivalent Stress ◽  
The Body ◽  
Temperature Fields ◽  
Transient Temperature ◽  
Shear Stresses ◽  
Transfer Coefficients ◽  
Thermal Transients ◽  
Power Cycling ◽  
Accelerated Thermal Cycling

During normal power cycling of the electronic equipment, the differing coefficients of thermal expansion result in differential elongations. Because each level of packaging is subject to mounting constraints, the differential strains result in bending and shear stresses. Repeated duty cycling can cause fatigue at joints, at interfaces between different materials, at interconnection locations, or cause delamination of composite materials. Accelerated Thermal Cycling (ATC) is done to simulate the fatigue failures that may arise because of this power cycling. The current practice is to determine ATC stresses by assuming that the temperatures of various layers are equal and constant. In this study, we have relaxed the isothermal assumption and we provide results for thermal stresses and strains in a first level package. This is accomplished by accurately determining the transient temperature fields in various layers of the package. Temperature variations for different heat transfer coefficients have also been calculated. The results indicate that realistic estimates of thermal stresses and strains are only possible with models that allow for temperature variation in the body of the package. High equivalent stress values are obtained at the chip-heat sink interface and in the bumps connecting the leads to the chip.

On the Thermal Stresses Generated in Cylindrical Shells With Application to Gas Turbine Combustors

1982 ◽  
Author(s):  
H. A. Nied
Keyword(s):  
Gas Turbine ◽  
Thermal Stresses ◽  
Longitudinal Direction ◽  
Temperature Fields ◽  
Shear Stresses ◽  
Gas Turbine Combustor ◽  
Closed Form Solutions ◽  
Bending Stresses ◽  
Cooling Hole ◽  
Axisymmetric Temperature

The thermal stresses generated in a cylindrical shell due to axisymmetric temperature fields, which vary in the longitudinal direction, are examined by using an influence function formulation. Closed form solutions for the longitudinal, hoop and shear stresses are derived for any axially varying temperature distribution expressible by a Fourier expansion. The thermal stresses generated in a typical cylindrical gas turbine combustor cooled by periodically spaced circumferential bands of cooling holes are investigated using the derived solutions. It is shown that a critical pitch in the cooling hole spacing can create high bending stresses at the cooling holes which could contribute to thermal fatigue failure.

scholarly journals The use of a solution of the inverse heat conduction problem to monitor thermal stresses

2019 ◽  
Vol 108 ◽  
pp. 01003
Author(s):  
Jan Taler ◽  
Piotr Dzierwa ◽  
Magdalena Jaremkiewicz ◽  
Dawid Taler ◽  
Karol Kaczmarski ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Transfer Coefficient ◽  
Power Plants ◽  
Thermal Stresses ◽  
Thermal Power ◽  
Temperature Fields ◽  
Thick Wall ◽  
Fluid Temperature ◽  
Unsteady Temperature

Thick-wall components of the thermal power unit limit maximum heating and cooling rates during start-up or shut-down of the unit. A method of monitoring the thermal stresses in thick-walled components of thermal power plants is presented. The time variations of the local heat transfer coefficient on the inner surface of the pressure component are determined based on the measurement of the wall temperature at one or six points respectively for one- and three-dimensional unsteady temperature fields in the component. The temperature sensors are located close to the internal surface of the component. A technique for measuring the fastchanging fluid temperature was developed. Thermal stresses in pressure components with complicated shapes can be computed using FEM (Finite Element Method) based on experimentally estimated fluid temperature and heat transfer coefficient

A Three-Dimensional Finite Difference Solution for the Thermal Stresses in Railcar Wheels

1969 ◽  
Vol 91 (3) ◽  
pp. 891-896 ◽  
Author(s):  
G. E. Novak ◽  
B. J. Eck
Keyword(s):  
Computer Program ◽  
Thermal Stresses ◽  
Three Dimensional ◽  
Transient Temperature ◽  
Shear Stresses ◽  
Radial Temperature ◽  
Closed Form Solutions ◽  
Brake Application ◽  
History Of ◽  
Thin Disks

A numerical solution is presented for both the transient temperature and three-dimensional stress distribution in a railcar wheel resulting from a simulated emergency brake application. A computer program has been written for generating thermoelastic solutions applicable to wheels of arbitrary contour with temperature variations in both axial and radial directions. The results include the effect of shear stresses caused by the axial-radial temperature gradients and the high degree of boundary irregularity associated with this type of problem. The program has been validated by computing thermoelastic solutions for thin disks and long cylinders; the computed values being in good agreement with the closed form solutions. Currently, the computer program is being extended to general stress solutions corresponding to the transient temperature distributions obtained by simulated drag brake applications. When this work is completed, it will be possible to synthesize the thermal history of a railcar wheel and investigate the effects of wheel geometry in relation to thermal fatigue.

Transient Elastic Thermal Stress Development During Laser Scribing of Ceramics

2000 ◽  
Vol 123 (1) ◽  
pp. 171-177 ◽  
Author(s):  
Michael F. Modest ◽  
Thomas M. Mallison
Keyword(s):  
Thermal Stresses ◽  
Continuous Wave ◽  
Elastic Stress ◽  
Three Dimensional ◽  
Thick Layer ◽  
Temperature Fields ◽  
Subsurface Cracks ◽  
Laser Scribing ◽  
Micro Cracks ◽  
Cutting Speeds

Lsaers are emerging as a valuable tool for shaping and cutting hard and brittle ceramics. Unfortunately, the large, concentrated heat flux rates that allow the laser to efficiently cut and shape the ceramic also result in large localized thermal stresses in a small heat-affected zone. These notable thermal stresses can lead to micro-cracks, a decrease in strength and fatigue life, and possibly catastrophic failure. In order to assess where, when, and what stresses occur during laser scribing, an elastic stress model has been incorporated into a three-dimensional scribing and cutting code. First, the code predicts the temporal temperature fields and the receding surface of the ceramic. Then, using the scribed geometry and temperature field, the elastic stress fields are calculated as they develop and decay during the laser scribing process. The analysis allows the prediction of stresses during continuous wave and pulsed laser operation, a variety of cutting speeds and directions, and various shapes and types of ceramic material. The results of the analysis show substantial tensile stresses develop over a thick layer below and parallel to the surface, which may be the cause of experimentally observed subsurface cracks.

scholarly journals Tribocatalytically-activated formation of protective friction and wear reducing carbon coatings from alkane environment

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Asghar Shirani ◽  
Yuzhe Li ◽  
Osman Levent Eryilmaz ◽  
Diana Berman
Keyword(s):  
Amorphous Carbon ◽  
Steel Substrate ◽  
Carbon Film ◽  
Substantial Reduction ◽  
Liquid Hydrocarbon ◽  
Shear Stresses ◽  
Friction Behavior ◽  
Uncoated Steel ◽  
Protective Films ◽  
Wear Coatings

AbstractMinimizing the wear of the surfaces exposed to mechanical shear stresses is a critical challenge for maximizing the lifespan of rotary mechanical parts. In this study, we have discovered the anti-wear capability of a series of metal nitride-copper nanocomposite coatings tested in a liquid hydrocarbon environment. The results indicate substantial reduction of the wear in comparison to the uncoated steel substrate. Analysis of the wear tracks indicates the formation of carbon-based protective films directly at the sliding interface during the tribological tests. Raman spectroscopy mapping of the wear track suggests the amorphous carbon (a-C) nature of the formed tribofilm. Further analysis of the tribocatalytic activity of the best coating candidate, MoN-Cu, as a function of load (0.25–1 N) and temperature (25 °C and 50 °C) was performed in three alkane solutions, decane, dodecane, and hexadecane. Results indicated that elevated temperature and high contact pressure lead to different tribological characteristics of the coating tested in different environments. The elemental energy dispersive x-ray spectroscopy analysis and Raman analysis revealed formation of the amorphous carbon film that facilitates easy shearing at the contact interface thus enabling more stable friction behavior and lower wear of the tribocatalytic coating. These findings provide new insights into the tribocatalysis mechanism that enables the formation of zero-wear coatings.

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