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A Novel Approach to the Elasto-Plastic Analysis of Residual Stresses for Layered Two-component Composite Coating Obtained by Hybrid Twin-Wire Arc Spraying

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Abstract

The distribution of residual stresses is a crucial factor in governing the performance of thermal-sprayed coatings. Even though this issue has been extensively investigated in previous reports involving homogeneous coatings, little progress has been made when it comes to composite coatings. Here, a novel type of elasto-plastic analytical model is proposed to study the residual stresses in a two-component composite coating prepared through thermal spraying process, in which the quenching stresses and thermal stresses are taken into consideration based on the assumption of layer-by-layer deposition. An arc-sprayed Fe-Al layered composite coating is applied as the model system for the case study. The results show that the distribution of residual stress in the Fe-Al two-component interlaced composite coating is quite different from that of a homogeneous thermal-sprayed coating. As the coating thickness increases, the difference becomes more significant. Benefiting from the improvement in residual stress distribution, it is confirmed by the analytical model and experimental investigation, that the two-component composite structure made of alternate layers of a hard steel and a soft aluminum can be used for forming thick coatings.

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Abbreviations

\(\alpha\) :

Coefficient of thermal expansion (K−1)

\(\Delta \varepsilon\) :

Misfit strain

E :

Young’s modulus

\(\varepsilon\) :

Strain

H d :

Strain hardening (Pa)

h :

Thickness of all deposited layers (m)

K :

Curvature (m−1)

n :

Number of layers

T :

Temperature (K)

\(\Delta T\) :

Difference between the initial splat temperature and deposition temperature (K)

t :

Thickness (m)

\(\delta\) :

Strain component

\(\sigma\) :

Stress (Pa)

v :

Poisson’s ratio

y :

Displacement, relative to the interface (m)

y e :

Neutral axial position, relative to the interface (m)

d, s :

First coating material deposit and substrate, respectively

dp :

Planar strain component for the deposit

e :

Equivalent

sp :

Planar strain component for the substrate

ind, inm :

Initial temperature of first and second coating material, respectively

K :

Bending (for strain)

i, j, n, c :

Correlated with the deposition of ith, jth, and nth layer and the final cooling, respectively

m :

For the second coating material

r :

Room temperature

Y :

Yielding (for stress)

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Acknowledgment

This work was financially supported by National Key R&D Program of China (2018YFC1902400).

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Authors and Affiliations

  1. Defense Innovation Institute, Academy of Military Science, Dongdajie No.53, Fengtai District, Beijing, 100071, China

    Yongxiong Chen, Ming Xia, Xin Cui & Xiubing liang

  2. School of Chemical Engineering and Technology, China University of Mining and Technology, Xuzhou, China

    Ming Xia

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Chen, Y., Xia, M., Cui, X. et al. A Novel Approach to the Elasto-Plastic Analysis of Residual Stresses for Layered Two-component Composite Coating Obtained by Hybrid Twin-Wire Arc Spraying. J Therm Spray Tech 31, 2435–2447 (2022). https://doi.org/10.1007/s11666-022-01444-7

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