Bonding mechanism from the impact of thermally sprayed solid particles

Power particles are mainly in solid state prior to impact on substrates from high velocity oxy-fuel (HVOF) thermal spraying. The bonding between particles and substrates is critical to ensure the quality of coating. Finite element analysis (FEA) models are developed to simulate the impingement process of solid particle impact on substrates. This numerical study examines the bonding mechanism between particles and substrates and establishes the critical particle impact parameters for bonding. Considering the morphology of particles, the shear-instability–based method is applied to all the particles, and the energy-based method is employed only for spherical particles. The particles are given the properties of widely used WC-Co powder for HVOF thermally sprayed coatings. The numerical results confirm that in the HVOF process, the kinetic energy of the particle prior to impact plays the most dominant role in particle stress localization and melting of the interfacial contact region. The critical impact parameters, such as particle velocity and temperature, are shown to be affected by the shape of particles, while higher impact velocity is required for highly nonspherical powder

Residual stress in laser cladded rail

To improve the fatigue life of components subject to loads with high surface strain gradients, it is possible to coat them with an alloy of higher durability. The present study focuses on the effect of cladding high value track components, made of a standard rail steel UIC 900A/grade 260, with a layer of a premium martensitic stainless steel to reduce wear and fatigue. The laser cladding process inevitably generates residual stresses in the clad and parent metal, which could be detrimental to the integrity of the component. Therefore, measurements to determine the residual stress state of cladded rail were performed using semi-destructive centre-hole and deep hole drilling and non-destructive neutron diffraction techniques. Subsequently, the effects of cycling loading and wear, representative of typical service loads, on the redistribution of the residual stress field were investigated. It was observed that laser cladding causes a triaxial compressive residual stress field in the clad and near the interface and a tensile stress field in the parent material. The stress field is shown to change when the first cycle of load is applied but reaches a steady state after only 10 cycles: After the 10th cycle there is no evidence that the clad continues accumulating strain which could indicate that there is low risk of ratcheting. Wear effect on residual stress redistribution was found to be local on the surface of the specimen only

Deposition Model of Thermal Spray Coatings

Abstract A three dimensional model of coating formation has been developed. Using the model we are able to simulate coating formation by deposition of large numbers of droplets. The properties of impacting particles are assumed to vary stochastically using a normal probability density function. Splat curl up is assumed to be the source of porosity formation. The model is able to predict coating porosity, thickness and roughness as a function of spray parameters.</jats:p