Thermo-Mechanical Analysis of Sprayed Layers Using the Finite Element Method

Abstract

The present paper presents an analysis performed in order to determine the thermo-mechanical behavior at the layer-substrate interface in case of thermal spraying, by using the ANSYS R15.0 software. The analysis was made on high alloyed steel samples thermal sprayed on one side. For the 1st sample, the material used for the deposited layer was ZrO2 stabilized with Y2O3 (ZrO2+20% Y2O3) using the HVOF process. The 2nd sample was sprayed with stellite using the plasma spraying process. This analysis follows the idea of temperature distribution along with the other characteristics that define the thermal state in an object: the heat quantities released or absorbed, thermal gradient and thermal flow. In order to determine the causes of thermal expansions or contractions, the analysis is followed by a stress analysis. The obtained results show that the interface stresses are lower in the case of stellite coating, both steel and stellite having closer thermo-physical characteristics than steel and YSZ also including the intermediate layer.