Abstract
In this article, a new concept of smart coating is presented, which enables failure prevention under thermo-mechanical fatigue loading by a simple coating without using any external devices. The feasibility of arresting fatigue crack propagation under thermo-mechanical loading is experimentally demonstrated for an Al–Si practical casting alloy by applying a simple and inexpensive coating prior to usage. An Sn alloy has been chosen as a coating material as a result of extensive screening tests. Valuable mechanistic insight has been gained from numerical simulation indicating that the crack driving force can be reduced by the crack closure mechanism induced by the impregnation of coating material.
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