Residual Stresses of Plasma Sprayed ZrC-Based Coatings during Path-by-path and Layer-by-layer Deposition: Simulation and Experimental Verification

doi:10.15541/jim20180450

Abstract

Abstract:

Commercial ANSYS14.5 software was used to simulate the residual stress characteristics in the deposition process of plasma sprayed ZrC-based coatings on the surface of C/C composite substrates. The simulation combined the mechanical model of composite beam adding laminate layer, and the finite element model of accumulation of path-by-path and layer-by-layer. Effects of SiC transition layer, second phase (SiC, MoSi₂) and coating thickness on residual stresses of the ZrC-based coatings were analyzed and validated by experiments. All results show that the SiC transition layer effectively relieve thermal mismatch stress between the coating and the substrate. Stress of the coating decreases gradually with the increase of coating thickness, which conforms to the stress relaxation and superposition law. There exist tensile stress in the coating, and compressive stress in the substrate. Moreover, compressive stress concentration is found at the interface edge, which is easly induced cracks formation and propagation along the interface. Therefor, our simulation method in present study could simulate actual spray process and predict residual stress of the coatings accurately.

Key words: plasma spray, ZrC-based coatings, finite element simulation, path-by-path and layer-by-layer deposition, residual stress

CLC Number:

TQ174

XIE Ling-Ling, NIU Ya-Ran, WANG Liang, CHEN Wen-Liang, ZHENG Xue-Bin, HUANG Zhen-Yi. Residual Stresses of Plasma Sprayed ZrC-Based Coatings during Path-by-path and Layer-by-layer Deposition: Simulation and Experimental Verification[J]. Journal of Inorganic Materials, 2019, 34(7): 768-774.

Figures/Tables 16

Fig. 1 Schematic of mechanic model of complex beam due to deposition of nth layer

Fig. 2 Model of deposition process of coatings

Fig. 3 Schematic of finite element mesh

Table 1 Thermo-physical performance parameters of the substrate and coating[16,17]

Material	T/ ℃	Ε/GPa	ρ/(kg·m^-3)	α/(×10^-6, K^-1)	ν	k/(W·m^-1·K^-1)	C/(J·kg^-1·K^-1)
C/C	25	70	1800	1.00	0.340	8.00	800
	200	-	-	3.58	-	8.13	934
	400	-	-	3.70	-	7.95	1115
	600	-	-	3.94	-	7.77	1239
	800	-	-	4.08	-	7.76	1344
	1000	-	-	4.20	-	8.21	1522
SiC	2300	448	3050	4.50	0.142	16.70	670
ZrC	20	348	6730	6.70	0.180	20.50	366
ZrC	3540	355	6730	6.70	0.191	20.50	366
MoSi₂	2030	440	6240	8.10	0.115	45.00	540

Fig. 4 Change of radial stresses along radial direction at substrate/coatings interface (tc=0.35 mm)

Fig. 5 Change of radial stresses along radial direction at the surface of coatings (tc=0.35 mm)

Fig. 6 Change of radial stresses along radial direction at transition layer /coatings interface (tc=0.35 mm)

Fig. 7 Change of radial stresses along radial direction at surface of coatings (tc=0.35 mm)

Fig. 8 Comparison of maximum axial stresses among coatings

Fig. 9 Comparison of maximum shear stresses among coatings

Fig. 10 Change of maximum equivalent stresses at coating surface

Fig. 11 Superposition principle of residual stresses[22]

Fig. 12 Surface morphologies of the coatings (a) ZS2; (b) ZrC; (c) ZM2

Fig. 13 Cross-section morphologies of coating on the C/C composites (a) and EDS mapping of Si distribution in the coating (b)

Fig. 14 Radial residual stress distribution in the ZM4 coating surface (a) Without SiC transition layer; (b) With SiC transition layer

Fig. 15 Schematic of interfacial peeling stress distributions of the coating (a) The maximum tensile stress at the edge; (b) The maximum compressive stress at the edge

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