A finite element (FE) based methodology is presented for simulating the high-velocity oxy-fuel (HVOF) coating process. The methodology involves a hybrid of explicit and implicit FE analyses to simulate both particle impact and layer deposition and thus furnish both temperature and residual stress distributions resulting from the process. The methodology is illustrated for an HVOF sprayed copper coating on a copper substrate and for a SS 316 HVOF sprayed coating on a SS 316 substrate.
ClyneT WResidual stresses in thick and thin surface coating In Encyclopaedia of Materials: Science and Technology, (Ed. MortensenA), 2001, section 4.1.3b (Elsevier, Oxford, UK).
2.
McGrannR T RGrevingD JShadleyJ RRybickiE FBodgerB ESomervilleD AThe effect of residual stress in HVOF tungsten carbide coatings on the fatigue life in bending of thermal spray coated aluminiumJ. Therm. Spray Technol., 1998, 7 (4), 546–552.
3.
WithersP JBhadeshiaH K DResidual stress part 1-measurement techniquesMater. Sci. Technol., 2001, 17, 355–365.
4.
BouarichaSLegouxJ.-G.MarcouxPBending behaviour of HVOF produced WC-17Co coatings: Investigated by acoustic emissionJ. Therm. Spray Technol., 2004, 13 (3), 405–414.
5.
BansalPShipwayP HLeenS BFinite element modelling of the fracture behaviour of brittle coatingsSurf. Coat. Technol., 2006, 200, 5318–5327.
6.
BuchmannMGadowRTabellionJExperimental and numerical residual stress analysis of layer coated compositesMater. Sci. Eng., 2000, A288, 154–159.
7.
TsuiY CClyneT WAn analytical model for predicting residual stresses in progressively deposited coatingsThin Solid Films, 1997, 306, 23–33.
8.
WenzelburgerMModelling of thermally sprayed coatings on light metal substrates: Layer growth and residual stress formationSurf. Coat. Technol., 2004, 180–181, 429–435.
9.
PinaJDiasALebrunJ LStudy by X-ray diffraction and mechanical analysis of the residual stress generation during thermal sprayingMater. Sci. Eng., 2003, A347, 21–31.
10.
BansalPShipwayP HLeenS BEffect of particle impact on residual stress development in HVOF sprayed coatingsJ. Therm. Spray Technol., 2006, 15 (4), 570–575.
11.
PlancheM PNormandBLiaoHRannouGCoddetCInfluence of HVOF spraying parameters on in-flight characteristics of inconel 718 particles and correlation with the electrochemical behaviour of the coatingSurf. Coat. Technol., 2002, 157, 247–256.
12.
HansonT CHackettC MSettlesG SIndependent control of HVOF particles velocity and temperatureJ. Therm. Spray Technol., 2002, 11 (1), 75–85.
13.
AzizS DChandraSImpact, recoil and splashing of molten metal dropletsInt. J. Heat Mass Transf., 2000, 43, 2842–2857.
14.
LiMChristofidesP DMulti-scale modeling and analysis of an industrial HVOF thermal spray processChem. Eng. Sci., 2005, 60, 3649–3669.
15.
ThorpeR JMcGregorLWangDThe JP-5000 HP/HVOF- the next generation HVOF. In Proceedings of the International Thermal Spray Conference, Essen, Germany, 2002, pp. 125–135.
16.
KawakitaJIsoyamaKKurodaSYumotoHEffects of deformability of HVOF sprayed copper particles on the density of resultant coatingsSurf. Coat. Technol., 2006, 200 (14–15), 4414–4423.
17.
BansalPShipwayPLeenS BResidual stresses in HVOF sprayed coatings - modelling the effect of spray parametersActa Mater., 2007, 55, 5089–5101.
18.
TotemeierT CWrightR NSwankW DResidual stresses in high-velocity oxy-fuel metallic coatingsMetall. Mater. Trans. A, 2004, 35A, 1807–1814.
19.
TotemeierT CEffect of high-velocity oxygen-fuel thermal spraying on the physical and mechanical properties of type 316 stainless steelJ. Therm. Spray Technol., 2005, 14 (3), 369–372.
20.
KurodaSTashiroYYumotoHTairaSFukanumaHTobeSPeening action and residual stresses in high-velocity oxygen fuel thermal spraying of 316L stainless steelJ. Therm. Spray Technol., 2001, 10 (2), 367–374.
21.
ShiJLiuC RThe influence of material models on finite element simulation of machiningJ. Manuf. Sci. Eng., 2004, 126 (4), 849–857.
22.
JohnsonG RCookW HA constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. In Proceedings of the 7th International Symposium on Ballistics, The Netherlands, 1983, pp. 541–547.
23.
WestE G (Ed.) Copper and its alloys, 1982 (Ellis Horwood Publishers, Chichester).
24.
BlomF JChurchJ MWelding simulation and helium damage modelling. In Proceedings of the International Conference on Metal Fabrication and Welding Technology, Nottingham, 2003 (available on CD-ROM).
MićunovićMAlbertiniCMontagnaniMHigh strain rate thermo-inelasticity of damaged AISI 316HInt. J. Damge Mech., 2003, 12, 267–303.
27.
Abaqus/Explicit user's manual, version 6.5–1, 2004 (H.K.S. Inc.).
28.
MeguidS AShagalGStranartJ C3D finite element analysis of strain-rate sensitive materials using multiple impingement modelInt. J. Impact Eng., 2002, 2 (27), 119–134.
29.
BolotRVerdyCCoddetCCornuDChoulantMAnalysis of thermal fluxes transferred by an impinging HVOF jet. In Proceedings of the International Thermal Spray Conference, Basel, Switzerland (Ed. LugscheiderE F), 2005, pp. 992–997 (DVS-Verlag, Düsseldorf).
30.
LeiYO'DowdN PWebsterG AFracture mechanics analysis of a crack in a residual stress fieldInt. J. Fract., 2000, 106, 195–216.
31.
YokoyamaKWatanabeMKurodaSGotohY In Proceedings of the International Thermal Spray Conference, Seattle, 2006 (available on CD-ROM).
32.
FanQWangLWangFWangQModelling of temperature and residual stress fields resulting from impacting process of a molten Ni particle onto a flat substrate. In Proceedings of the International Thermal Spray Conference, Basel, Switzerland (Ed. LugscheiderE F), 2005, pp. 275–279 (DVS-Verlag, Düsseldorf).
