401 Computer Predictions of Thermo-Mechanical Behavior and Residual Stresses in Spray Coating Process

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This paper presents a numerical method in order to forecast thermo-mechanical behavior and the residual stress in the thermal spray coating process by using of high velocity oxygen fuel(HVOF). A set of coupled equations of the heat conduction and stress/strain and solidification based on the metallo-thermo-mechanical theory is introduced into the simulation of thermal spraying. Here, A inelastic constitutive equation with capacity to represent relation of stress/strain during rapid solidification is employed. The numerical modeling based on the finite element method is proposed to solve the heat conduction associated with solidification in the sprayed layer and residual stresses on the interface between multi-layer materials, especially. In this paper, the simulated results of the temperature filed, solidified domain and residual stresses in the sprayed layer including interfacial combinations between substrate and spray layer are presented, and the validity of the calculated results is discussed in comparison with the measured results by using of X-ray diffraction.