碳钢热喷涂镍沉积凝固过程热力耦合场的数值模拟及温度应力场的分布规律

为了进一步弄清热喷涂残余应力产生的机理、预测与控制技术,以碳钢表面热喷涂镍为例,对镍沉积凝固冷却过程进行了合理的假设和简化。利用ANSYS平台,采用热力耦合计算,模拟了涂层冷却过程,获得了温度场和应力场分布规律,分析了涂层上某些特征点的温度和应力随时间变化的情况,并探讨了基体预热温度和涂层厚度对涂层/基体界面应力的影响。结果表明,涂层温度沿中心向边缘逐渐降低,随时间延长呈降低趋势;基体温度随时间的变化呈先增加后降低趋势;涂层主要承受残余压应力作用,随基体温度升高,残余应力呈减小趋势,随涂层厚度增加,残余应力呈增大趋势。     

喷涂

后期冷却是导致热喷涂层产生残余应力的主要原因。很少考虑喷射颗粒在凝固后冷却到基体温度这个初始冷却问题。提出了两类冷却模型以预测基体温度对残余应力的影响。考虑了三个连续的机理:喷射颗粒凝固后收缩,在喷涂期间和喷涂后涂层的变形。当涂层的膨胀系数比基体小时,高的基体温度将导致压应力;反之,则产生     

等离子喷涂ZrC基涂层逐道逐层沉积残余应力模拟与实验验证

采用商用ANSYS14.5软件, 依据复合梁增层力学模型, 采用逐道逐层累积模型模拟了C/C复合材料表面等离子喷涂ZrC基涂层沉积残余应力的特征, 分析了SiC过渡层、第二相(SiC, MoSi₂)和涂层厚度对ZrC基涂层残余应力的影响, 并进行了实验验证。结果表明, SiC过渡层有效缓解了涂层与基体的热失配应力。涂层体系的应力随着涂层厚度的增加逐渐减小, 符合应力松弛和叠加规律。在涂层内部的径向应力以拉应力为主, 基体中主要为压应力, 且在界面边缘存在压应力集中的极限区域, 易使涂层产生裂纹并沿界面扩展。该模拟采用逐道逐层累积的方法更逼近实际喷涂过程, 能更准确预测涂层的残余应力。     

涂层基体条件对梯度涂层残余应力影响研究

采用有限元法，对结构一定的Al/Ni-ZrO2梯度涂层在基体条件改变时涂层的残余应力进行了分析，结果表明，基体材料的热膨胀系数对涂层的残余应力有显著的影响，对于基体为圆柱形的涂层，其基体与涂层界面的残余应力梯度，最大轴向拉应力均随热膨胀系数的增大而线性增大，表面纯陶瓷层与次层界面残余应力梯度则随之减小，增大基体的直径和厚度，可缓和涂层残余应力，并在基体直径为36mm,厚度为20mm时各残余应力基本稳定。     

热喷涂零件界面裂纹扩展行为影响因素研究

热喷涂技术在提高构件寿命等方面得到了广泛应用,但界面裂纹的存在对零件寿命的影响尤其明显。本工作利用有限元法研究了残余应力、涂层厚度以及初始裂纹长度等因素对界面裂纹扩展的影响。研究结果表明:残余压应力的增加会导致临界载荷的降低,促使裂纹尖端应力相角增大,更易萌生界面裂纹;而残余拉应力的增加会导致临界载荷的升高,促使裂纹尖端应力相角降低,更易萌生垂直于界面的裂纹。此外,厚涂层易产生平行于界面的裂纹,以剪切失效为主导;薄涂层易产生垂直于界面的裂纹,以拉伸失效为主导。初始裂纹长度越长越易出现涂层与基体的剥离,导致涂层的失效。通过三点弯曲实验对不同初始长度的裂纹进行验证,实验结果与有限元模拟结果相近,验证了有限元模拟的正确性,为精确控制热喷涂零件界面的裂纹扩展提供了科学依据和理论基础。     

Y-TZP/LZAS微晶玻璃功能梯度涂层残余应力分析

为了提高钢基体微晶玻璃涂层的韧性,设计了Y-TZP/LZAS微晶玻璃功能梯度涂层。运用有限元软件,分析了梯度层数目、梯度层厚度和层间3Y-TZP体积组分差等参数对涂层/基体界面残余热应力的影响。结果表明,涂层表层主要分布为径向压应力;在涂层/基体界面的边缘区域应力集中较为严重;涂层/基体界面处的径向应力、轴向应力和剪切应力以及梯度层数目、梯度层厚度和3Y-TZP体积组分差均有密切关系。最后通过涂搪法制备了梯度涂层,测试了涂层表面残余应力,并与有限元结果对比,以验证模拟的准确性。     

热喷涂构件中残余应力的理论分析

本文发展了一种新的分析涂层结构(平板、梁)热残余应力的模型,可以研究骤冷过程(Quenching)和冷却过程(Cooling)在涂层结构内引发的残余应力分布。与以往模型相比,其优势在于:它可以考虑源于喷涂过程的涂层孔隙率、温度梯度等因素对于涂层和基底内残余应力的影响。其中孔隙率和温度分布由计算机模拟涂层沉积过程得到。另外,当基底的材料和几何参数被固定时,我们分析了诸如涂层的理想模量、厚度、热膨胀系数等参数,对于涂层结构中最终残余应力分布的改变机理。     

基于Nastran等离子喷涂厚壁零件涂层中残余应力分析

基于有限元数值分析对等离子喷涂不同的基体上的喷涂陶瓷涂层和金属涂层中残余应力进行了分析,结果表明:涂层与基体体系的最大应力分布在接触界面附近,由中心线向外依次递增,在边缘处达到最大值。在体系中心区域正应力沿厚度方向逐渐减小,而在涂层中应力分布则趋于线性;建立了涂层中各残余应力分量的准数方程式,准数方程式与数值计算结果显示了较好的吻合,而且对于不同基体-涂层体系均是适用的。无因次最大径向应变、无因次剪应力侵入深度和无因次最大径向应力的大小均取决于涂层厚度与弹性模量的积和基体半径与基体弹性模量积之间比值,而影响无因次径向最大剪应力的大小的根本因素为涂层厚度与光斑半径的比值。     

Y-TZP/LZAS微晶玻璃功能梯度涂层残余应力的有限元分析

设计了Y-TZP/LZAS微晶玻璃功能梯度涂层,使用有限元软件分析了成分分布指数、梯度层数目和梯度层厚度等参数对涂层/基体界面残余热应力的影响。结果表明:功能梯度材料的最佳成分梯度指数为m=1;涂层最佳层数为3-5层;涂层最佳厚度为1-1.5 mm;涂层表层主要分布为径向压应力;在涂层/基体界面的边缘区域应力集中较为严重;涂层/基体界面处的径向应力、轴向应力和剪切应力与成分分布指数、梯度层数目和梯度层厚度有密切的关系。用涂搪法制备了梯度涂层,用X射线衍射法(XRD)测试了涂层表面残余应力,验证了有限元结果的准确性。     

工程结构表面涂层残余应力的测量

在工程结构中广泛采用表面涂层技术，由于涂层材料与基体材料的热膨胀系数等特性不同，涂层存在一定的残余应力，易使涂层爆裂甚至剥落，造成涂层失效，结构报废，本文研究电测盲孔法测量涂层的残余应力，用来分析产生残余应力的各种影响因素。     

Röntgenografische Eigenspannungsmessungen an plasmagespritzten Wärmedämmschichten aus Zirkonoxid vor und nach thermischer und mechanischer Beanspruchung

X-Ray Stress Measurements on Plasma Sprayed Zirkonia Thermal Barrier Coatings Turbine blades for aero engines with plasma sprayed zirconia thermal barrier coatings were subjected to typical component loads as thermal fatigue and creep. Before and after testing residual surface stresses in the coatings were determined by X-ray stress measurements. Different substrate temperatures during the plasma spraying process caused tensile or compressive stresses on the surfaces of the thermal barrier coatings. Coatings with compressive stresses failed after only a few thermal cycles whereas those with tensile stresses sustained 700 to 1500 cycles without visible damage. Thermal fatigue and creep tests lead to stress changes reducing tensile stresses and increasing compressive stresses.     

Impact of the non-homogenous temperature distribution and the coatings process modeling on the thermal barrier coatings system

The present study deals with a numerical investigation of the residual stresses arising during the plasma-sprayed coatings process and their effects on the final stress state of the thermal barrier coatings system (TBCs) during service. A new thermo-mechanical finite element model (FEM) has been designed to function using a non-homogenous temperature distribution. Several phenomena are taken into account in the model such as: residual stresses generated during the spraying of coatings, morphology of the top-coat/bond-coat interface, oxidation at the top-coat/bond-coat interface, thermal mismatch of the material components, plastic deformation of the bond-coat and creep of all layers during thermal cycling. These phenomena induce local stresses in the TBCs that are responsible of micro-crack propagation during cooling and thermal cycling, specifically near the ceramic/metal interface.     

Effect of Differential Thermal Expansion Coefficient on Stresses Generated in Coating

Two different spraying powders [81FVNS and 80% (443)+20% (105)] were plasma sprayed on two types of substrates (AISI 316 and Ti) in order to verify the effect of differential thermal expansion coefficient (DTEC) between coating and substrate on the final residual stresses generated in the coating. Modulus of elasticity (E) was evaluated for the substrates and coatings (as a composite beam). Free-standing coatings were used to measure the thermal expansion coefficient, as a function of temperature, of the actual coatings with all defects, impurities and typical lamella structure. The results show that the residual stresses seems to be less dependent on the linear thermal expansion coefficients mismatching between substrate and coating, reflecting the importance of the other sources of stresses. i.e. quenching or deposition stresses induced during spraying. The suitable heat treatment condition of the coated samples may release some or most of the residual stresses. However in some cases the sign of the stress was completely changed as a result of neglecting the quenching stresses.     

含FGM的涂层结构中热残余应力的分析与优化

本文利用有限元方法和优化理论,对含ＦＧＭ（Ｆｕｎｃｔｉｏｎａｌｌｙ　Ｇｒａｄｅｄ　Ｍａｔｅｒｉａｌｓ）层的热喷涂构件中的残余应力进行了数值分析,并获得了ＦＧＭ内各组份体积含量分布的最优化形式和参数ｐ。同时,我们也研究了喷涂构件的几何形状、涂层及基底的材料性能对于ｐ的影响规 律。在本文的分析中,考虑了基底材料和ＦＧＭ的塑性变形以及其性能对于温度的依赖。本文 的工作将有利于含ＦＧＭ层的热喷涂构件的设计与生产。     

等离子喷涂热障涂层残余应力的实验与模拟研究

分别采用真空和大气等离子体喷涂工艺在GH3128镍基高温合金基材表面制备CoNiCrAlY结合层和氧化钇部分稳定的氧化锆陶瓷层组成热障涂层。采用有限元模拟计算了涂层的残余应力, 研究了基材预热对打底层与陶瓷层界面应力分布的影响规律。结果表明, 预热基材可以显著地降低陶瓷顶层内部产生的残余拉应力。采用钻孔法测量了涂层中的残余应力并与模拟结果作定量比较, 结果表明: 有限元模拟计算结果与实验测量结果能较好吻合。     

Residual stress and thermal cycling of planar solid oxide fuel cells

Abstract

The published literature relating to damage to planar solid oxide fuel cells caused by thermally induced stresses and thermal cycling is reviewed. This covers reported studies of thermal cycling performance and stresses induced by temperature gradients and differences in thermal expansion coefficients in typical planar SOFC configurations, namely electrolyte supported; anode supported and inert substrate supported cells. Generally good agreement is found between electrolyte residual stresses measured by X-ray diffraction or cell curvature and stresses calculated from simple thermo-elastic analysis. Finite element modelling of temperature distributions in cells and stacks in steady state operation are well advanced and capable of being extended to compute stress distributions. Failure criteria are then discussed for laminated cell structures based on critical energy release rate fracture mechanics models developed originally for coatings. However, in most cases the data required to apply the models quantitatively (such as elastic moduli of actual laminated material and fracture energies of materials and interfaces) are not available. Where data are available there are inconsistencies that require resolution. Seals are critical components in many planar solid oxide fuel cell configurations, but again there are discrepancies in experimental mechanical properties and the role of internal stresses in their fracture. In addition, there is as yet no firm evidence that thermal cycling damage involves any true materials fatigue process.     

MANUFACTURE AND PROPERTIES OF PLASMA SPRAYED Cr2O3

Low porosity (some %) chromia coatings have been plasma sprayed onto several substrates by atmospherical and vacuum plasma spraying. Different phases appear in the sprayed product; metallic Cr and the metastable tetragonal Cr₃O₄ phase have been identified. A post annealing treatment completely removes these phases. This behaviour can be correlated with differences between the coefficients of thermal expansion comparing the as-sprayed with the annealed material. Hot Isostatic Pressing improves the interface bonding between coating and substrate and reduces porosity as can be seen from the results of metallographical investigations. If aluminium is present in the substrate alloy, chemical interactions have been observed. First results from measurements of residual stresses in coatings show the influence of coefficients of expansion and substrate temperature during spraying. Gastightness of the sprayed chromia could not yet be established.     

Evaluation of residual stresses in PVD-coatings. Part 2

The values of residual stresses in PVD-coatings of titanium, aluminum and niobium nitrides are determined by the flexible specimen method. An experimental-and-calculation procedure for separating the structural and thermal components of residual stresses is proposed that allows one to determine the thermal expansion coefficients of the coating materials and a general level of residual stresses in coatings on a substrate of any material. The dependence of the residual stress on the roughness of the substrate surface is established. The possibility of adjusting the level of residual stresses in coatings by the discrete surface topography formation is shown.     

Modeling of residual stresses variation with thermal cycling in thermal barrier coatings

Thermal barrier coatings (TBCs) are commonly used as protective coatings for engine metal components to improve performance. Many investigations have shown that residual stresses in TBCs applications play an important role, but the residual stresses are mainly obtained by simulation method. As we know, there are a few analytical solutions of residual stress in TBCs system. In this paper, a new two-dimensional analytical solution has been obtained under the condition of non-linear coupled effects of temperature gradient, thermal fatigue, deposited residual stress, thermally grown oxide (TGO) thickening, elasto-plasticity deformation and creep deformation of TBC. Moreover, the influences of bending moment and curvature on stress variation in TBCs are considered during thermal cycling. The calculated results are in agreement with the prior experimental results.     

Thin film fracture: Ti-coating-Be-substrate bond failure

The role of microstructure in the fracture of the bond between vapour-deposited thin film coatings and substrates will be modelled to a first approximation using classical fracture mechanics principles. Vapour-deposited coatings are composed of a grain structure with varying orientations. The effect of differing degrees of texture on the bond strength between the coating and its substrate will be considered in this analysis. Incorporated in stress calculations will be the residual stresses arising from the thermal contraction of the coating, an applied tensile stress normal to the coating surface (as that in an adherence pull test) and the critical stress needed for coating-substrate bond failure.