Numerical Modeling of Selected Thermal Spraying Issues Tomasz Chmielewski, Dariusz Golański

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TABLE OF CONTENTS

List of major designations and abbreviations  9

Preface 11

Introduction 15

1. Thermal spraying of layers and coatings 17

1.1. Methods of depositing layers and coatings 18

1.2. Arc spraying  20

1.3. Plasma spraying 23

1.4. Flame spraying  26

1.4.1. Flame spraying at subsonic velocities  26

1.4.2. Flame spraying at supersonic velocities  28

1.5. Laser spraying 36

1.6. Cold spraying 39

1.7. Laser alloying and remelting 42

1.7.1. Laser alloying  42

1.7.2. Laser remelting of coatings  43

1.8. Comparison of thermal spraying methods 44

2. Selected properties of sprayed coatings 49

2.1. Coating formation process 49

2.2. Coating adhesion 51

2.2.1. Effect of surface preparation  52

2.2.2. Effect of temperature  52

2.2.3. Effect of kinetic energy  53

2.2.4. Effect of the physical and chemical properties of materials 54

2.3. Residual stresses in surface layers  55

2.4. Residual stresses due to thermal mismatch 60

3. Feedstock materials for spraying 64

4. Testing of thermally deposited coatings by flame and detonation methods 69

4.1. Preliminary testing of sprayed coatings by flame and detonation methods  71

4.2. Characterization of feedstock materials 71

4.3. Stresses in the coating–substrate system 73

4.4. Construction of an instrument for testing the deflection of a coated substrate after the spraying process 75

4.5. Spraying titanium coatings on ceramic substrates 76

4.6. Determination of residual stresses in sprayed coatings 77

4.6.1. Titanium coatings   77

4.6.2. Ti+Al2O3 composite coatings  79

4.7. Numerical analysis of residual stresses in titanium and composite coatings  80

4.8. Temperature field during cooling of the coating–substrate system 85

4.8.1. Object of study  86

4.8.2. Assumptions for numerical calculations 87

4.8.3. Calculation results  88

4.8.4. Comparative analysis of temperature distribution calculation results  93

4.9. Stress investigation in Ti and Ti+Al2O3 coatings sprayed on Al2O3 substrate by deto-nation gun method (D-gun)  99

4.9.1. Feedstock materials  99

4.9.2. Detonation spraying parameters  100

4.9.3. Measurements of deflection in specimens after detonation spraying  101

4.9.4. Stresses in the sprayed coating based on the curvature of the specimen  102

4.10. Conclusions 106

5. Residual stress modelling in the thermal spraying process  109

5.1. Introduction – physical modelling of the process and generation of residual stresses  109

5.2. Methodology adopted for modelling residual stresses in thermally sprayed coatings  112

5.3. Particle impact modelling using ANSYS-AUTODYN 115

5.4. Modelling of particle impact on the substrate  119

5.5. Impact of Ti particles on the Al2O3 substrate and particles on the sublayer by detona¬tion spraying 120

5.6. Thermo-mechanical model of the thermal spraying process  126

5.6.1. Temperature distributions in the Ti–Al2O3 coating–substrate system, detonation spraying  131

5.6.2. Stress distributions in the Ti–Al2O3 coating–substrate system, detonation spraying  133

5.6.3. The influence of the substrate preheating temperature on the stresses in the Ti–Al2O3 coating–substrate system  136

5.7. The effect of the impact velocity on the residual stresses in the Ti–Al2O3 coating–sub¬strate system  145

5.7.1. Results of dynamic calculations for the impact of a feedstock material particle on a ceramic substrate  147

5.7.2. Impact of Ti coating particles against the Ti coating sublayer  152

5.7.3. Results of temperature distribution calculations for different particle impact ve¬locities 156

5.7.4. Results of specimen deflection and stress distribution calculations for different particle impact velocities  159

5.7.5. Summary of particle spray velocity effects  163

5.8. Conclusions 164

6. Modelling the impact of a single particle on the substrate  166

6.1. Model description  166

6.2. Assumptions for the Ti particle model on ceramic and metal substrates 173

6.2.1. Mode l of spraying Ti particles on Al2O3 ceramic substrate (V = 500 m/s) 174

6.2.2. Model of spraying Ti particles on Al2O3 ceramic substrate (V = 800 m/s) 180

6.3. Comparative analysis of particle impact simulations of ceramic and metallic substra¬tes 186

6.3.1. Titanium particle 186

6.3.2. Copper particle 192

6.3.3. Particle geometry after impact  199

6.4. Modelling of the impact of a heated Ti particle on a ceramic substrate 199

6.4.1. Geometric model  199

6.4.2. Model deformation simulation results 202

6.4.3. Temperature distribution in the Ti particle–Al2O3 substrate system  206

6.4.4. Distribution of reduced stresses in the Ti particle–Al2O3 substrate system 207

6.5. Conclusions 211

7. Coating testing and modelling of residual stresses in the thermal spraying process using the HVOF method  214

7.1. Testing of metal coatings sprayed on Al2O3 ceramic substrate 214

7.2. Test object  214

7.3. Spraying station 215

7.4. Structural studies 219

7.5. Coating wettability tests  224

7.5.1. Wettability tests in argon  226

7.5.2. Wettability tests in vacuum  227

7.5.3. Conclusions  228

7.6. Residual stress tests in the coating–substrate system  228

7.6.1. Determination of residual stresses based on the curvature of the specimen  229

7.6.2. Research on residual stresses in coatings using the X-ray method  231

7.7. Conclusions  234

7.8. Numerical and experimental analysis of residual stresses generated in metallic coatings deposited by HVOF on an Al2O3 substrate  235

7.8.1. Impact of Ti particles on the Al2O3 substrate 235

7.8.2. Temperature distributions in the Ti, Cu, Ni coating system  239

7.8.3. Stress distributions in the Ti (Cu, Ni) coating–Al2O3 substrate system  241

7.8.4. Conclusions  245

8. Investigation of strains and stresses in sprayed Ti and Cu coatings using grating inter-ferometry  247

8.1. Grating interferometry method 247

8.2. Specimen grating technology 249

8.3. Automatic analysis of fringe images 250

8.4. Measuring station 251

8.5. Measurement procedure  253

8.6. Measurements on a titanium coating sprayed on an Al2O3 substrate 254

8.6.1. Measurement of displacements in the measuring field of 14.3×14.3 mm prior to cutting 255

8.6.2. Measurement of displacements in the measuring field of 14.3×14.3 mm after cutting 256

8.6.3. Measurement of displacements in the measuring field of 14.3×14.3 mm after the second cutting 259

8.6.4. Measurements in a small measuring field (3.7×3.7 mm) 262

8.7. Measurements on a copper coating sprayed on an Al2O3 substrate  264

8.7.1. Measurement of displacements in the measuring field of 14.3×14.3 mm prior to cutting  264

8.7.2. Measurement of displacements in the measuring field of 14.3×14.3 mm after cutting  265

8.7.3. Measurements in a small measuring field (3.7×3.7 mm) after the second cutting 268

8.8. Strain comparison for Cu and Ti coated specimens  270

8.9. Modelling of deflection and residual stresses in Cu/Al2O3 and Ti/Al2O3 systems before and after cutting the plate  273

8.9.1. Cu–Al2O3 coating–substrate model  274

8.9.2. Ti–Al2O3 coating–substrate model  276

8.10. Comparison of determined residual stresses 279

8.11. Conclusion 279

9. Summary and conclusions  282

Bibliography 291

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