| Abstract: |
Developing a reliable concept for the computational simulation of residual stresses development in thermally sprayed coatings requires the merging of several modeling principles that accounts for the different phenomena encountered during the coating buildup process. Those phenomena are specifically; the development of compressive stresses in the substrate because of the impacting coating particles, the deformation and solidification of the impacting particles to form splats on the substrate surface and finally the quenching of the solidified splats and cooling down of the substrate-coating composite. Those phenomena can be simulated on stand-alone basis using, respectively, explicit dynamics, computational fluid dynamics and thermomechanical FEA modeling. For those models to realistically account for the effects of the different spraying parameters on the aforementioned phenomena, implementation of an extensive experimental database, whose input variables are the utilized spraying parameters and whose output variables constitute the input data for created models, is necessary. This work was concerned with establishing interconnecting series of models that account for each of the aforementioned phenomena. The series of models was equipped with experimental databases so that they enable the versatile testing of the effects of spraying parameters variation on the attained residual stresses. The models were developed with consideration of atmospheric plasma spraying yet are adaptable to be used for other powder depositing spraying processes.
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