Optimization design and residual thermal stress analysis of PDC functionally graded materials

The distribution of thermal stresses in functionally graded polycrystalline diamond compact (PDC) and in single coating of PDC are analyzed respectively by thermo-mechanical finite element analysis (FEA). It is shown that they each have a remarkable stress concentration at the edge of the interfaces. The diamond coatings usually suffer premature failure because of spallation, distortion or defects such as cracks near the interface due to these excessive residual stresses. Results showed that the axial tensile stress in FGM coating is reduced from 840 MPa to 229 MPa compared with single coating, and that the shear stress is reduced from 671 MPa to 471 MPa. Therefore, the single coating is more prone to spallation and cracking than the FGM coating. The effects of the volume compositional distribution factor (n) and the number of the graded layers (L) on the thermal stresses in FGM coating are also discussed respectively. Modelling results showed that the optimum value of the compositional distribution factor is 1.2, and that the best number of the graded layers is 6.

Analysis of Residual Thermal Stress in CVD-W Coating as Plasma Facing Material

Chemical vapor deposition-tungsten （CVD-W） coating covering the surface of the plasma facing component （PFC） is an effective method to implement the tungsten material as plasma facing material （PFM） in fusion devices. Residual thermal stress in CVD-W coating due to thermal mismatch between coating and substrate was successfully simulated by using a finite element method （ANSYS 10.0 code）. The deposition parametric effects, i.e., coating thickness and deposition temperature, and interlayer were investigated to get a description of the residual thermal stress in the CVD-W coating-substrate system. And the influence of the substrate materials on the generation of residual thermal stress in the CVD-W coating was analyzed with respect to the CVD-W coating application as PFM. This analysis is beneficial for the preparation and application of CVD-W coating.

Residual Thermal Stresses of Laser Cladding of Intermetallic-Ceramic Composite Coatings

The stresses in laser cladding of Ni3Al-WC composite coating co and in heat affect zone (HAZ) σh have been induced based on considering the influences of laser processing parameters power P and beam traverse speed v.According to the calculated results, certain limits of P and v are necessary in order to obtain crack free coatings. It agrees well with the experimental results.

Proportional Limit Stress and Residual Thermal Stress of 3D SiC/SiC Composite

Proportional limit stress （PLS） and residual thermal stresses （RTS） of 3D SiC/SiC composite were investigated. PLS was obtained by four different methods from the monotonic stress-strain response curve to get a convincing value. RTS in the SiC matrix was quantified by solving the geometric intersection point of the regression lines of hysteresis loops from the periodical loading-unloading-reloading cycle test curve. Classical ACK model and analytical formulas were used to analytically calculate the PLS and RTS of 3D SiC/ SiC composite. Good agreement between the experimental results and the analytical calculation was observed. And relationship between the PLS and the RTS of 3D SiC/SiC was discussed.

Thermal residual stress of polycrystalline diamond compacts

Thermal residual stresses in polycrystalline diamond compact(PDC)cutter arising from the difference in thermal expansion between the polycrystalline diamond(PCD)and the supporting tungsten carbide substrate after sintering at high pressure and high temperature were investigated using finite element simulation,laboratory tests and theoretical analysis.The obtained results show that although compressive residual stresses exist both in the interface of PCD table and in the most region of PCD table surface, the tensile residual stress,which is a fatal shortage to PDC,can also occur near the outer diameter area of PCD table,and the maximum value is 690 MPa.Distribution of tensile stress in the PCD table is given through experimental results,which is well consistent with the numerical results.This finding may be significant in designing new PDC cutters with lower residual stress and high cutting behavior.

Thermal residual stresses and stress distributions under tensile and compressive loadings of short fiber reinforced metal matrix composites

The thermal residual stresses and the stress distributions of short fiber reinforced metal matrix composite under tensile and compressive loadings were studied using large strain axisymmetric elasto plastic finite element method. It is demonstrated that the thermal residual stresses can result in asymmetrical stress distributions and matrix plasticity. The thermal residual stresses decrease the stress transfer in tension and enhance the stress transfer in compression. The fiber volume fraction has more important effects on the thermal residual stresses and the stress distributions under tensile and compressive loadings than the fiber aspect ratio and the fiber end distance. [

Effect of thermal residual stresses on yielding behavior under tensile or compressive loading of short fiber reinforced metal matrix composite

Using large strain two dimension axisymmetric elasto plastic finite element method and the modified law of mixture, the effects of thermal residual stresses on the yielding behavior of short fiber reinforced metal matrix composite and their dependencies on the material structure parameters (fiber volume fraction, fiber aspect ratio and fiber end distance) were studied. It is demonstrated that the stress strain partition parameter can be used to describe the stress transfer from the matrix to the fiber. The variation of the second derivation of the stress strain partition parameter can be used to determine the elastic modulus, the proportion limit, the initial and final yield strengths. In the presence of thermal residual stress, these yielding properties are asymmetric and are influenced differently by the material structure parameters under tensile and compressive loadings.

Effect of C/Mo Duplex-coating on Thermal Residual Stresses in SiCf/Ti2AlNb Composites

Three-dimensional finite element physical models considering the layered distribution of materials at the interface were developed to study the effect of the coating system on distributions of thermal residual stresses in SiCf/Ti2AlNb composites.Two coating systems were comparatively studied,namely C coating and C/Mo duplex-coating.The thermal residual stresses after 1 080 ℃/1 h solution treatment and 800 ℃/20 h ageing treatment in the composites were also analyzed.The experimental results show that Mo coating can decrease thermal residual stress magnitude in the matrix.However,it would increase the thermal residual stresses in the interfacial reaction layer of TiC.The change of radial thermal residual stress in TiC layer is inconspicuous after solid solution and ageing treatment,but the hoop and axial thermal residual stresses increase obviously.However,the heat treatment can obviously reduce hoop and axial thermal residual stresses of the matrix,which is benefit to restrain the initiation and propagation of cracks in the matrix.

An Application of the Modified Shear Lag Model to Study the Influence of Thermal Residual Stresses on the Stiffness and Yield Strength of Short Fiber Reinforced Metal Matrix Composites

The modified shear lag model proposed recently was applied to calculate thermal residual stresses and subsequent stress distributions under tensile and compressive loadings. The expressions for the elastic moduli and the yield strengths under tensile and compressive loadings were derived which take account of thermal residual stresses. The asymmetries in the elastic modulus and the yield strength were interpreted using the derived expressions and the obtained results of the stress calculations. The model predictions have exhibited good agreements with the experimental results and also with the other theoretical predictions

Effects of residual stress and dislocation on tensile deformation behavior of SiC_w/Al composites

By means of XRD, Instron electronic tensile machine and TEM, the dislocation states and strengthening mechanisms of SiC whisker reinforced pure aluminum matrix composites were studied with different annealing treatment processes and matrixes. The results showed that the strengthening mechanisms of SiC w/p Al composite and SiC w/6061Al composites are different. For the SiC w/p Al composite, the thermal residual stress plays more important role in strengthening than the high density dislocations in matrix; for the SiC w/6061Al composite, the dislocation strengthening and precipitation are main strengthening factors.

Crack patterns corresponding to the residual strength plateau of ceramics subjected to thermal shock

The formation strength plateau of ceramics is addressed. A set of of 99A1203 are conducted, mechanism of the residual subjected to thermal shock thermal shock experiments where the thin specimens of 1 mm× 10 mm×50 mm exhibit parallel through edge cracks, and thus permit quantitative measurements of the crack patterns. The cracks evolve with the severity of ther- mal shock. It is found that there is a correlation between the length and density of the thermal shock cracks. The increase of crack length weakens the residual strength, whereas the increase of crack density improves it. In a considerably wide temperature range, the two contrary effects just counteract each other; consequently a plateau appears in the variation curve of the residual strength. A comparison between the numerical and experimental results of the residual strength is made, and they are found in good agreement. This work is helpful to a deep understanding of the thermal shock failure of ceramics.

Finite element analysis of stress distribution and burst failure of SiC_f/Ti-6Al-4V composite ring

A three-dimensional cyclic symmetry finite element model of titanium-matrix composites（TMCs） ring was developed to investigate the stress distribution and burst failure. The effects of fiber volume fractions, reinforced areas, thermal residual stresses and two different temperatures on stress distribution were studied. The burst speed was obtained through analyzing the hoop tensile stresses under a series of rotating speeds. The results indicate that at the two different temperatures, the influences of fiber volume fractions and reinforced areas on stress level and distribution are different. Some proposals are provided for the structure design of the TMCs ring. With regard to thermal residual stresses, a larger reinforced area is an advisable choice for design of the ring at higher temperature.

FEM analysis on the effect of cobalt content on thermal residual stress in polycrystalline diamond compact(PDC)

Thermal residual stress in Polycrystalline Diamond Compacts （PDCs） is mainly caused by the mismatch in the Coefficients of Thermal Expansion （CTE） between the polycrystalline diamond （PCD） layer and WC-Co substrate. In the PCD layer, the CTE of cobalt exhibit magnitudes four times larger than those of diamond. Cobalt content in the PCD layer has important effects on the thermal residual stress of PDCs. In this work, the effects of cobalt content on thermal residual stress in PCDs were investi- gated by the Finite Element Method （FEM）. The simulation results show that the thermal residual stress decreases firstly, and then increases with increasing cobalt content （1 vo1.%-20 vol.%）, which reaches a minimum value when the cobalt content is about 10 vol.%. The FEM analysis results are in agreement with our experimental results. It will provide an effective method for further designing and optimizing PDC properties.

Evolution of thermo-physical properties of diamond/Cu composite materials under thermal shock load

In this paper, the two-flume method was used to study the change laws of the thermal conductivity and thermal expansion coefficient of diamond/Cu composite materials with 100, 300, and 500 cycle numbers, under the action of thermal shock load between-196 and 85 °C; the X-ray diffraction method（XRD） was used to study the change of the residual stress in the thermal shock process of the diamond/Cu composite materials; and the evolution of the fracture microstructure with different thermal shock cycle numbers was observed through scanning electron microscopy（SEM）. The results of the study show that the increase of the binder residue at the interface reduces the thermal shock stability of the diamond/Cu composite materials. In addition, under the thermal shock load between-196 and 85 °C, the residual stress of the diamond/Cu composite materials increases continuously with the increase of the cycle numbers, the increase of residual stress leads to a small amount of interface debonding, an increase of the interfacial thermal resistances, and a decrease of the constraints of low-expansion component on material deformation, thus the thermal conductivity decreases slightly and the thermal expansion coefficient increases slightly.

Novel design and composition optimization of self-lubricating functionally graded cemented tungsten carbide cutting tool material for dry machining

The functionally graded cemented tungsten carbide (FGCC) is a suitable material choice for cutting tool applications due to balanced hardness and fracture toughness.The presence of cobalt and CaF2 composition gradient in FGCC may enhance mechanical as well as antifriction properties.Therefore,structural design of selflubricating FGCC was proposed using Power law composition gradient model and thermal residual stresses (TRSs) as a key parameter.Wherein,S.Suresh and A.Mortensen model was adopted for estimation of TRS,and optimum composition gradient was identified at Power law exponent n =2.The designed material displayed compressive and tensile TRS at surface and core respectively;subsequently fabricated by spark plasma sintering and characterized via scanning electron microscope (SEM),indentation method.The agreement between experimental and analytical values of TRS demonstrated the effectiveness of intended design model in the composition optimization of self-lubricating FGCC.This work will be helpful in implementation of dry machining for clean and green manufacturing.

Atomistic simulation on the generation of defects in Cu/SiC composites during cooling

The coefficient of thermal expansion(CTE)mismatch between the reinforcement and the matrix results in thermal residual stresses and defects within metal-matrix composites(MMCs)upon cooling from the processing temperature to ambient temperature.The residual stresses and thermally induced defects play an important role in the mechanical properties of MMCs,it is critical to understand the mechanism of defect formation and evolution.This study provides atomistic simulations to reveal the generation of thermal residual stresses,dislocation and incomplete stacking fault tetrahedron(ISFT)during cooling in the idealized Cu/SiC composites.We found that dislocations are generated explosively in a certain temperature range during cooling,which results in a non-linear relationship between dislocation density and temperature.The combined effect of the stresses induced by CTE mismatch and the thermodynamic state of the metal leads to the rapid generation of dislocations.The Shockley partial and the highly stable stair rod are the two dominant dislocation structures.The immobile stair-rod dislocations and the highly stable ISFTs formed in the initial high temperature stage inhibit further development of plastic deformation.The present results provide new insights into the defect formation mechanism and the dislocation strengthening mechanism of MMCs caused by thermal mismatch between constituents.