Modeling Residual Stress Development in Thermal Spray Coatings: Current Status and Way Forward

Abba A. Abubakar, Abul Fazal M. Arif*, Khaled S. Al-Athel, S. Sohail Akhtar, Javad Mostaghimi

*Corresponding author for this work

Research output: Contribution to journalReview articlepeer-review

35 Scopus citations

Abstract

An overview of analytical and numerical methods for prediction of residual stresses in thermal spray coatings is presented. The various sources and mechanisms underlying residual stress development in thermal spray coatings are discussed, then the various difficulties associated with experimental residual stress measurement in thermal spray coatings are highlighted. The various analytical and numerical models used for prediction of residual stresses in thermal spray coatings are thoroughly discussed. While analytical models for prediction of postdeposition thermal mismatch stresses are fully developed, analytical quenching and peening stress models still require extensive development. Various schemes for prediction of residual stresses using the finite element method are identified. The results of the various numerical and analytical models are critically analyzed, and their accuracy and validity, when compared with experiments, are discussed. Issues regarding the accuracy and applicability of the models for predicting residual stresses in thermal spray coatings are highlighted, and several suggestions for future development of the models are given.

Original languageEnglish
Pages (from-to)1115-1145
Number of pages31
JournalJournal of Thermal Spray Technology
Volume26
Issue number6
DOIs
StatePublished - 1 Aug 2017

Bibliographical note

Publisher Copyright:
© 2017, ASM International.

Keywords

  • analytical model
  • birth–death technique
  • finite element method
  • numerical model
  • residual stress
  • thermal spray coatings

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Surfaces, Coatings and Films
  • Materials Chemistry

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