A hybrid implicit-explicit finite element methodology for coating formation in the high-velocity oxy-fuel spraying process

Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications

Volumn 221, Issue 4, 2007, Pages 285-297

  Bansal, P ^a   Shipway, P H ^a   Leen, S B ^a  

^a UNIVERSITY OF NOTTINGHAM   (United Kingdom)

Author keywords

Copper; Finite element; High velocity oxy fuel; Particle impact; Residual stress; SS 316

Indexed keywords

COMPUTER SIMULATION; COPPER; FINITE ELEMENT METHOD; RESIDUAL STRESSES; VELOCITY;

COATING FORMATION; COPPER COATING; LAYER DEPOSITION; OXY-FUEL SPRAYING PROCESS;

SPRAYED COATINGS;

EID: 36749052821     PISSN: 14644207     EISSN: None     Source Type: Journal    
DOI: 10.1243/14644207JMDA159     Document Type: Article

References (32)

1. Clyne, T. W. Residual stresses in thick and thin surface coating. In Encyclopaedia of Materials: Science and Technology, (Ed. A. Mortensen), 2001, section 4.1.3b (Elsevier, Oxford, UK).
2. McGrann, R. T. R., Greving, D. J., Shadley, J. R., Rybicki, E. F., Bodger, B. E., and Somerville, D. A. The effect of residual stress in HVOF tungsten carbide coatings on the fatigue life in bending of thermal spray coated aluminium. J. Therm. Spray Technol., 1998, 7(4), 546-552.
3. Withers, P. J. and Bhadeshia, H. K. D. Residual stress part 1-measurement techniques. Mater. Sci. Technol., 2001, 17, 355-365.
4. Bouaricha, S., Legoux, J.-G., and Marcoux, P. Bending behaviour of HVOF produced WC-17Co coatings: investigated by acoustic emission. J. Therm. Spray Technol., 2004, 13(3), 405-414.
5. Bansal, P., Shipway, P. H., and Leen, S. B. Finite element modelling of the fracture behaviour of brittle coatings. Surf. Coat. Technol., 2006, 200, 5318-5327.
6. Buchmann, M., Gadow, R., and Tabellion, J. Experimental and numerical residual stress analysis of layer coated composites. Mater. Sci. Eng., 2000, A288, 154-159.
7. Tsui, Y. C. and Clyne, T. W. An analytical model for predicting residual stresses in progressively deposited coatings. Thin Solid Films, 1997, 306, 23-33.
8. Wenzelburger, M. Modelling of thermally sprayed coatings on light metal substrates: layer growth and residual stress formation. Surf. Coat. Technol., 2004, 180-181, 429-435.
9. Pina, J., Dias, A., and Lebrun, J. L. Study by X-ray diffraction and mechanical analysis of the residual stress generation during thermal spraying. Mater. Sci. Eng., 2003, A347, 21-31.
10. Bansal, P., Shipway, P. H., and Leen, S. B. Effect of particle impact on residual stress development in HVOF sprayed coatings. J. Therm. Spray Technol., 2006, 15(4), 570-575.
11. Planche, M. P., Normand, B., Liao, H., Rannou, G., and Coddet, C. Influence of HVOF spraying parameters on in-flight characteristics of inconel 718 particles and correlation with the electrochemical behaviour of the coating. Surf. Coat. Technol., 2002, 157, 247-256.
12. Hanson, T. C., Hackett, C. M., and Settles, G. S. Independent control of HVOF particles velocity and temperature. J. Therm. Spray Technol., 2002, 11(1), 75-85.
13. Aziz, S. D. and Chandra, S. Impact, recoil and splashing of molten metal droplets. Int. J. Heat Mass Transf., 2000, 43, 2842-2857.
14. Li, M. and Christofides, P. D. Multi-scale modeling and analysis of an industrial HVOF thermal spray process. Chem. Eng. Sci., 2005, 60, 3649-3669.
15. Thorpe, R. J., McGregor, L., and Wang, D. The JP-5000 HP/HVOF- the next generation HVOF. In Proceedings of the International Thermal Spray Conference, Essen, Germany, 2002, pp. 125-135.
16. Kawakita, J., Isoyama, K., Kuroda, S., and Yumoto, H. Effects of deformability of HVOF sprayed copper particles on the density of resultant coatings. Surf. Coat Technol., 2006, 200(14-15), 4414-4423.
17. Bansal, P., Shipway, P., and Leen, S. B. Residual stresses in HVOF sprayed coatings - modelling the effect of spray parameters. Acta Mater., 2007, 55, 5089-5101.
18. Totemeier, T. C., Wright, R. N., and Swank, W. D. Residual stresses in high-velocity oxy-fuel metallic coatings. Metall. Mater. Trans. A, 2004, 35A, 1807-1814.
19. Totemeier, T. C. Effect of high-velocity oxygen-fuel thermal spraying on the physical and mechanical properties of type 316 stainless steel. J. Therm. Spray Technol., 2005, 14(3), 369-372.
20. Kuroda, S., Tashiro,Y., Yumoto, H., Taira, S., Fukanuma, H., and Tobe, S. Peening action and residual stresses in high-velocity oxygen fuel thermal spraying of 316L stainless steel. J. Therm. Spray Technol., 2001, 10(2), 367-374.
21. Shi, J. and Liu, C. R. The influence of material models on finite element simulation of machining. J. Manuf. Sci. Eng., 2004, 126(4), 849-857.
22. Johnson, G. R. and Cook, W. H. A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. In Proceedings of the 7th International Symposium on Ballistics, The Netherlands, 1983, pp. 541-547.
23. West, E. G. (Ed.) Copper and its alloys, 1982 (Ellis Horwood Publishers, Chichester).
24. Blom, F. J. and Church, J. M. Welding simulation and helium damage modelling. In Proceedings of the International Conference on Metal Fabrication and Welding Technology, Nottingham, 2003 (available on CD-ROM).
25. Marshall, P. Austenitic stainless steel - microstructure and mechanical properties, 1984 (Elsevier Applied Science Publishers, London).
26. Mic̀unovic̀, M., Albertini, C., and Montagnani, M. High strain rate thermo - inelasticity of damaged AISI316H. Int. J. Damge Mech., 2003, 12, 267-303.
27. Abaqus/Explicit user's manual, version 6.5-1, 2004 (H.K.S. Inc.).
28. Meguid, S. A., Shagal, G., and Stranart, J. C. 3D finite element analysis of strain-rate sensitive materials using multiple impingement model. Int. J. Impact Eng., 2002, 2(27), 119-134.
29. Bolot, R., Verdy, C., Coddet, C., Cornu, D., and Choulant, M. Analysis of thermal fluxes transferred by an impinging HVOF jet. In Proceedings of the International Thermal Spray Conference, Basel, Switzerland (Ed. E. F. Lugscheider), 2005, pp. 992-997 (DVS-Verlag, Düsseldorf).
30. Lei, Y., O'Dowd, N. P., and Webster, G. A. Fracture mechanics analysis of a crack in a residual stress field. Int. J. Fract., 2000, 106, 195-216.
31. Yokoyama, K., Watanabe, M., Kuroda, S., and Gotoh, Y. In Proceedings of the International Thermal Spray Conference, Seattle, 2006 (available on CD-ROM).
32. Fan, Q., Wang, L., Wang, F., and Wang, Q. Modelling of temperature and residual stress fields resulting from impacting process of a molten Ni particle onto a flat substrate. In Proceedings of the International Thermal Spray Conference, Basel, Switzerland (Ed. E. F. Lugscheider), 2005, pp. 275-279 (DVS-Verlag, Düsseldorf).