Study of the effect of substrate surface curvature and thickness on residual stress of plasma sprayed coatings by finite element method
In order to investigate the effect of substrate surface curvature and thickness on the residual stress of plasma sprayed coatings,this paper established models with different substrate surface curvatures and thick-nesses,and applied the finite element method to carry out the simulation on the different models for spraying NiCrAl coatings on TC4 titanium alloy surfaces under the control of constant spraying process parameters.The results show that the curvature of the substrate surface and the thickness of the substrate do not affect the overall distribution pattern of the residual stress,but have an effect on its magnitude.The distribution of residual stress on the bonding surface of the coating and the substrate shows a pattern of high stress at the ed-ges and low stress at the center.When the substrate surface curvature κ increases from 0 mm-1 to 1/9 mm-1,the larger residual stress values on the bonding surface decrease significantly.In the case of the same curva-ture of the substrate surface,an increase in the substrate thickness can result in a significant decrease in the extreme value of the residual stress on the bonding surface.In the range of parameters selected in this paper,increasing the substrate surface curvature and the substrate thickness can reduce the equivalent residual stress extremes on the bonding surface and help improve the bonding quality of the coating and the substrate.
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