Residual Stresses in Thermal Spray Coatings and Their Effect on Interfacial Adhesion: A Review of Recent Work

Clyne, T.W.; Gill, Shubhra

doi:10.1007/bf02645271

Cited by 430 publications

(179 citation statements)

References 57 publications

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“…In the case of plasma spraying, however, the quench component of the residual stress is high due to the larger temperature difference between the spray particle and the substrate [11,15]. The net coating residual stress therefore remains tensile, even with relatively high-velocity particles impacting the surface.…”

Section: Discussionmentioning

confidence: 99%

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FeAl and Mo–Si–B intermetallic coatings prepared by thermal spraying

2004

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FeAl and Mo-Si-B intermetallic coatings for elevated temperature environmental resistance were prepared using high-velocity oxy-fuel (HVOF) and air plasma spray (APS) techniques. For both coating types, the effect of coating parameters (spray particle velocity and temperature) on the microstructure and physical properties of the coatings was assessed. Fe-24Al (wt.%) coatings were prepared using HVOF thermal spraying at spray particle velocities varying from 540 m/s to 700 m/s. Mo-13.4Si-2.6B coatings were prepared using APS at particle velocities of 180 and 350 m/s. Residual stresses in the HVOF FeAl coatings were compressive, while stresses in the APS Mo-Si-B coatings were tensile. In both cases, residual stresses became more compressive with increasing spray particle velocity due to increased peening imparted by the spray particles. The hardness and elastic moduli of FeAl coatings also increased with increasing particle velocity, again due to an increased peening effect. For Mo-Si-B coatings, plasma spraying at 180 m/s resulted in significant oxidation of the spray particles and conversion of the T1 phase into amorphous silica and α-Mo. The T1 phase was retained after spraying at 350 m/s.

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Section: Discussionmentioning

confidence: 99%

“…Average coating and substrate stresses were calculated from the measured curvature using the simple beam bending model described in Ref. [11]. The required physical parameters (elastic modulus)were measured on free-standing coating specimens (described below).…”

Section: Methodsmentioning

confidence: 99%

FeAl and Mo–Si–B intermetallic coatings prepared by thermal spraying

2004

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“…Later on, based on Stoney formula various models have been developed [12][13][14][15][16][17][18] to address numerical computations of uniform residual strain in the coating. Recently, a model using computational techniques identified that the corrosion at the interface of coating and substrate is inhibited by compressive residual stress in coating due to the contraction of open corrosion paths in the coatings [19].…”

Section: Introductionmentioning

confidence: 99%

Analysing the coupled effects of compressive and diffusion induced stresses on the nucleation and propagation of circular coating blisters in the presence of micro-cracks

Nazir

Khan

Stokes

2016

Engineering Failure Analysis

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This paper presents the delamination of coating with micro-cracks under compressive residual stress coupled with diffusion induced stress. Micro-cracks in coating provide a passage for corrosive species towards the coating-substrate interface which in turn produces diffusion induced stress in the coating. Micro-cracks contract gradually with increasing compressive residual stress in coating due to thermal expansion mismatch which blocks the species diffusion towards the interface. This behaviour reduces the diffusion induced stress in the coating while the compressive residual stress increases. With further increase in compressive residual stress, micro-cracks reach to the point, where they cannot be constricted any further and a high compressive residual stress causes the coating to buckle away from the substrate resulting in delamination and therefore initiating blistering. Blistering causes the contracted micro-cracks to wide open again which increases diffusion induced stress along with high compressive residual stress. The high resultant stress in coating causes the blister to propagate in an axis-symmetric circular pattern. A two-part theoretical approach has been utilised coupling the thermodynamic concepts with the mechanics concepts. The thermodynamic concepts involve the corrosive species transportation through micro-cracks under increasing compression, eventually causing blistering, while the fracture mechanics concepts are used to treat the blister growth as circular defect propagation. The influences of moduli ratio, thickness ratio, thermal mismatch ratio, poisson's ratio and interface roughness on blister growth are discussed. Experiment is reported for blistering to allow visualisation of interface and to permit coupled (diffusion and residual) stresses in the coating over a full range of interest. The predictions from model show excellent, quantitative agreement with the experimental results.

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“…As such, this chapter does not cover synthesis of films, coatings, or deposits that are made by aerosol processes, including suspended droplets or particles deposited in a molten state on surfaces at high temperatures by flames, plasma, or torches, or at low temperatures by high-pressure sprays or electrospraying. This technology is called "thermal spray coating, " as reviewed by Clyne and Gill (1996), or just "spray coating" or "combustion chemical vapor deposition" (Hunt et al, 1993);and Tricoli and colleagues (2010) have recently reviewed its use for gas sensors. This chapter also does not discuss the manufacture of optical fibers involving oxidation of precursor vapors and deposition of fine silica-based particles and eventual fiber drawing (Rowell, 1986).…”

Section: Introductionmentioning

confidence: 99%

Aerosol Science and Technology: History and Reviews

Ensor¹

2011

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Aerosol Science and Technology: History and Reviews captures an exciting slice of history in the evolution of aerosol science. It presents in-depth biographies of four leading international aerosol researchers and highlights pivotal research institutions in New York, Minnesota, and Austria. One collection of chapters reflects on the legacy of the Pasadena smog experiment, while another presents a fascinating overview of military applications and nuclear aerosols. Finally, prominent researchers offer detailed reviews of aerosol measurement, processes, experiments, and technology that changed the face of aerosol science. This volume is the third in a series and is supported by the American Association for Aerosol Research (AAAR) History Working Group, whose goal is to produce archival books from its symposiums on the history of aerosol science to ensure a lasting record. It is based on papers presented at the Third Aerosol History Symposium on September 8 and 9, 2006, in St. Paul, Minnesota, USA.

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Residual Stresses in Thermal Spray Coatings and Their Effect on Interfacial Adhesion: A Review of Recent Work

Cited by 430 publications

References 57 publications

FeAl and Mo–Si–B intermetallic coatings prepared by thermal spraying

FeAl and Mo–Si–B intermetallic coatings prepared by thermal spraying

Analysing the coupled effects of compressive and diffusion induced stresses on the nucleation and propagation of circular coating blisters in the presence of micro-cracks

Aerosol Science and Technology: History and Reviews

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