Simultaneous measurement of coating thickness and deposition stress during thermal spraying

Katayama, Seiji; Fukushima, Takeshi; Kitahara, Shigeru

doi:10.1016/0040-6090(88)90127-7

Cited by 89 publications

(17 citation statements)

References 4 publications

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“…The substrate-curvature method based on Stoney formula has been widely used in various applications (e.g., Carlotti et al, 1997;Lacquaniti et al, 1997;Krulevitch et al, 1996;Hunsche et al, 2001;Oka et al, 2003;Menzel et al, 2005). Kuroda et al (1988Kuroda et al ( , 1990 have also utilized the formula for TS coatings. The simple form of Stoney formula makes determinations of material properties straightforward.…”

Section: Introductionmentioning

confidence: 99%

Determination of nonlinear properties of thermal sprayed ceramic coatings via inverse analysis

Nakamura

Liu

2007

International Journal of Solids and Structures

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A robust procedure to estimate nonlinear mechanical properties of thermally sprayed (TS) ceramic coatings is introduced. Such a method is valuable particularly for TS coatings since each may possess unique properties depending upon its processing condition. Traditionally, their responses have been assumed as linear elastic (isotropic or anisotropic) except in very high temperature environments where softening may occur. However, recent inspections revealed their properties to be more accurately characterized as nonlinear elastic. It appears their distinctive morphology consisting of cracks and interfaces are responsible for such a response. In this work, a versatile procedure to identify nonlinear properties of thermally sprayed coatings is developed. First, a suitable stress-strain model is proposed and then a nonlinear bi-material beam solution is derived. Afterward, an inverse analysis technique is utilized to process the measured curvature-temperature to extract the unknown parameters. Prior to implementing in actual specimens, a detailed simulation study is performed to verify the method's accuracy as well as robustness. This computational analysis closely replicates deposition processes of TS coatings. With the successful verification, actual curvature measurement of TS yttria-stabilized zirconia (YSZ) coating is used to determine the nonlinear properties. The estimated results clearly reveal a significant nonlinearity of the TS coating. The main advantage of this procedure is that it requires essentially no specimen preparation and allows continuous measurements after TS deposition. Furthermore, the data interpretation does not require complex computational models and calculations. This streamlined process makes the present method attractive when evaluations of many specimens are required. The present procedure can be also extended to identify nonlinear properties of other coatings/films on substrates.

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Section: Introductionmentioning

confidence: 99%

Determination of nonlinear properties of thermal sprayed ceramic coatings via inverse analysis

Nakamura

Liu

2007

International Journal of Solids and Structures

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“…The measurement of in situ beam curvature during TS coating deposition was first demonstrated by Kuroda 5 and followed by detailed modeling of the layerby-layer stress building process by Tsui and Clyne. 4,19,20 The technique was further expanded on by Matijicek and Sampath 6,7 and correlated with x-ray and neutron-based techniques.…”

Section: Stress Evolution-coating Deposition and Residual Stressesmentioning

confidence: 99%

“…In recent years, the use of in situ beam curvature measurements during deposition is prevalent in advanced laboratories and being adopted in manufacturing, which provides a first-hand account of coating formation dynamics through extraction of layer-by-layer stress evolution, as well as elastic properties of the deposited coating. [4][5][6][7] All of these sensors have allowed for greater insight into the processing-property-performance correlation, by allowing coating specialists to understand the various interplays between the hardware and feedstock selection to what the final coating properties and expected performance are. Such a methodology, termed process mapping, [8][9][10] has been a useful tool for rapid optimization of desired coating properties and enables the design for damage-tolerant coatings in a systematic fashion as opposed to a brute force, bottom-up optimization.…”

Section: Opportunitymentioning

confidence: 99%

Structurally Integrated, Damage-Tolerant, Thermal Spray Coatings

Vackel

Dwivedi

Sampath

2015

JOM

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Thermal spray coatings are used extensively for the protection and life extension of engineering components exposed to harsh wear and/or corrosion during service in aerospace, energy, and heavy machinery sectors. Cermet coatings applied via high-velocity thermal spray are used in aggressive wear situations almost always coupled with corrosive environments. In several instances (e.g., landing gear), coatings are considered as part of the structure requiring system-level considerations. Despite their widespread use, the technology has lacked generalized scientific principles for robust coating design, manufacturing, and performance analysis. Advances in process and in situ diagnostics have provided significant insights into the process-structure-property-performance correlations providing a framework-enhanced design. In this overview, critical aspects of materials, process, parametrics, and performance are discussed through exemplary studies on relevant compositions. The underlying connective theme is understanding and controlling residual stresses generation, which not only addresses process dynamics but also provides linkage for process-property relationship for both the system (e.g., fatigue) and the surface (wear and corrosion). The anisotropic microstructure also invokes the need for damage-tolerant material design to meet future goals.

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“…However, some basic understanding of the mechanism of stress generation in plasma spraying is essential and in-situ curvature measurement of a strip-shaped substrate has exemplified its usefulness. Figure 8 shows a schematic diagram of the first in-situ curvature measuring instrument reported by Kuroda, where a strip-shaped substrate is fixed onto a pair of knife edges and the displacement at the center of the rear surface is measured by a contacting displacement sensor (7) . The substrate temperature is also measured by a thermocouple spot-welded to the substrate.…”

Section: In-situ Curvature Measurementmentioning

confidence: 99%

Multi-scale Phenomena and Structures Observed in Fabrication of Thermal Barrier Coatings by Using Plasma Spraying

Katayama

Murakami

Watanabe

et al. 2010

JMMP

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Thermal barrier coatings (TBC) fabricated by plasma spray can exhibit a wide range of microstructures due to differences in feedstock powders and spraying conditions. Since different microstructures naturally result in different thermal and mechanical properties and service life as thermal barrier coatings, it is of great importance to understand the relationship among the feedstock characteristics, spray conditions and the coating microstructures. Recent research efforts of the author's group to understand fundamental phenomena in plasma spraying of TBC are reviewed from microscopic to macroscopic viewpoints, i.e., direct observation of single droplet impact of molten zirconia by an ultra fast video camera, detection of acoustic emission (AE) signals during plasma spraying by using laser AE technique, and in-situ measurement of the curvature and temperature of a substrate during plasma spraying, from which strain-stress relationships and residual stresses of TBC can be evaluated.

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Simultaneous measurement of coating thickness and deposition stress during thermal spraying

Cited by 89 publications

References 4 publications

Determination of nonlinear properties of thermal sprayed ceramic coatings via inverse analysis

Determination of nonlinear properties of thermal sprayed ceramic coatings via inverse analysis

Structurally Integrated, Damage-Tolerant, Thermal Spray Coatings

Multi-scale Phenomena and Structures Observed in Fabrication of Thermal Barrier Coatings by Using Plasma Spraying

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