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The quality of coatings, produced by thermal spraying processes, considerably decreases with the occurrence of higher residual stresses, which are especially pronounced for complex workpiece geometries. To understand the occurring effects and to aid in the planning of coating processes, simulations of the highly transient energy flux of the HVOF spray gun into the substrate are of great value. In this article, a software framework for the simulation of nonlinear heat transfer during (HVOF) thermal spraying is presented. One part of this framework employs an efficient GPU-based simulation algorithm to compute the time-dependent input boundary conditions for a spray gun that moves along a complex workpiece of arbitrary shape. The other part employs a finite-element model for a rigid heat conductor adhering to the computed boundary conditions. The model is derived from the fundamental equations of continuum thermodynamics where nonlinear temperature-depending heat conduction is assumed.

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Sheet bulk metal forming processes are applied in order to produce tailored workpieces at high quality. Thereby, effort is made to optimise frictional and wear behaviour by designing the structures of the contact surfaces. Numerical process analysis can evoke a deeper under‐standing of the functionality of such surface structures. In this contribution, a finite element framework for the simulation of wear and the determination of effective frictional behaviour of structured surfaces at finite deformations is proposed. The modelling of wear is realised by pre‐ and postprocessing of an underlying representative contact problem at the meso‐scale. Thereby, elasto‐plastic material behaviour is assumed. A number of simulations with different parameterisations of a sinusoidal contact surface are carried out in order to demonstrate the influence of surface topology, which additionally depends on the state of wear, on the effective frictional behaviour. (© 2016 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)