Application of multiscale modeling in the coating formation simulation of APS PYSZ TBCs |
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Authors: | E Lugscheider K Bobzin R Nickel |
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Affiliation: | (1) Surface Engineering Institute, RWTH Aachen University, Augustinerbach 4-22, 52062 Aachen, Germany |
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Abstract: | The process parameters of atmospheric plasma spraying (APS) influence the coating formation and properties of partially yttria
stabilized zirconia (PYSZ) thermal barrier coatings (TBC). Simulations can be used to investigate this dependency and to design
the coating process for a targeted production of TBCs. A whole process simulation was realized by modeling the linked subprocesses:
plasma torch, plasma free jet, powder particles characteristics, and coating formation. The coating formation can be described
by model approaches with different physical assumptions and geometric scales. One approach is the simulation of single powder
particles hitting the substrate surface. An alternative macroscale finite element model (FEM) model approach is applied in
the coating formation simulation. A group of particles is pooled in a splash that is dependent on the precalculated particle
distribution in front of the substrate. A third modeling approach is applied to calculate effective mechanical and thermodynamical
properties of coatings dependent on the experimentally obtained or calculated microstructure of the PYSZ TBC, which is based
on different homogenization methods. The application of three simulation approaches in the whole process simulation of APS
is discussed; advantages and disadvantages are elucidated. Results based on simulation and experiments are presented for a
variation of process parameters. Missing links in the multiscale approach are detected to make suggestions for future modeling
and simulation work.
This article was originally published inBuilding on 100 Years of Success, Proceedings of the 2006 International Thermal Spray Conference (Seattle, WA), May 15–18, 2006, B.R. Marple, M.M. Hyland, Y.-Ch. Lau, R.S. Lima, and J. Voyer, Ed., ASM International, Materials
Park, OH, 2006. |
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Keywords: | atmospheric plasma spray thermal barrier coatings coating formation simulation multiscale modeling numerical homogenization |
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