Calculation of high-speed abrasion forces for ceramic coatings based on the Hertzian contact model

Aero engine seal coatings can effectively improve the air tightness of aircraft engines and increase fuel efficiency.However,due to the frictional forces between the blades and the coating,the coating often flakes off,resulting in damage to the blades and causing eco-nomic losses.Therefore,it is necessary to analyze the friction between the blades and the coating.In this paper,three ceramic-based high-temperature seal coatings with different polyphenylene ester contents and a pure Yttria-stabilised zirconia coating were prepared by atmo-spheric plasma spraying(APS).The hardness and modulus of elasticity of the coated surfaces were obtained by hardness and modulus of elasticity tests,and the coatings were subjected to high-speed touch abrasion tests.The Hertzian contact model was used to calculate the maximum normal contact load on the coating during the process.The test values were compared with the theoretical values and it was found that the calculated values were always greater than the test values.In order to make the Hertzian contact model more accurate in calculating the touching and abrasion forces,the contact coefficients in the Hertzian contact model were optimized.Substituting the optimized coeffi-cients into the Hertzian contact model,the results show that the calculated results after optimizing the coefficients are much closer to the test values,with deviations from the test values ranging from 1%to 38%.

Modeling and Optimization of Surface Roughness of Epoxy/Nanoparticles Composite Coating

In power plants,flue gases can cause severe corrosion damage in metallic parts such as flue ducts,heat exchangers,and boilers.Coating is an effective technique to prevent this damage.A robust fuzzy model of the surface roughness(Ra and Rz)of flue gas ducts coated by protective composite coating from epoxy and nanoparticles was constructed based on the experimental dataset.The proposed model consists of four nanoparticles(ZnO,ZrO2,SiO2,and NiO)with 2%,4%,6%,and 8%,respectively.Response surface methodology(RSM)was used to optimize the process parameters and identify the optimal conditions for minimum surface roughness of this coated duct.To prove the superiority of the proposed fuzzy model,the model results were compared with those obtained by ANOVA,with the coefficient of determination and the root-mean-square error(RMSE)used as metrics.For Ra,for the first output response,using ANOVA,the coefficient-of-determination values were 0.9137 and 0.4037,respectively,for training and prediction.Similarly,for Rz,the second output response,the coefficient-of-determination results were 0.9695 and 0.4037,respectively,for training and prediction.In the fuzzy modeling of Ra,for the first output response,the RMSE values were 0.0 and 0.1455,respectively,for training and testing.The values for the coefficient of determination were 1.00 and 0.9807,respectively,for training and testing.The results prove the superiority of fuzzy modeling.For modeling the second output response Rz,the RMSE values were 0.0 and 0.0421,respectively,for training and testing,and the coefficient-of-determination values were 1.00 and 0.9959,respectively,for training and testing.

Volatile Organic Compound Emissions from Surface Coating Facilities: Characterization of Facilities, Estimation of Emission Rates, and Dispersion Modeling of Off-Site Impacts

Surface coating facilities are major sources of volatile organic compounds (VOCs) in urban areas. These VOCs can contribute to ground-level ozone formation, and many are hazardous air pollutants (HAPs), including xylene, ethylbenzene, and toluene. This project was conducted in order to provide information for updating the Texas Commission on Environmental Quality (TCEQ), USA, permit by rule for Surface Coating Facilities. Project objectives were: 1) To develop a database of information regarding surface coating facilities in Texas;2) To estimate maximum emission rates for various VOC species from surface coating facilities in Texas;3) To conduct dispersion modeling to estimate off-site impacts from surface coating facilities. The database was developed using 286 TCEQ permit files authorizing surface coating facilities in Texas during 2006 and 2007. The database was designed to include information important for estimating emission rates, and for using as inputs to the dispersion model. Hourly and annual emissions of volatile organic compounds (VOCs), particulate matter (PM), and exempt solvents (ES) were calculated for each permitted entity/ company in the database, according to equations given by TCEQ. Dispersion modeling was then conducted for 3 facility configurations (worst-case stack height, good practice stack height, and fugitive emissions), for urban and rural dispersion parameters, for 8-hour and 24-hour operating scenarios, and for 1-hour, 24-hour, and annual averaging times, for a total of 36 scenarios. The highest modeled concentrations were for the worst-case stack height, rural dispersion parameters, 24-hour operation scenario, and 1-hour averaging time. 108 specific chemical species, which are components of surface coatings, were identified as candidates for further health impacts review.

Modeling of Fracture Toughness of Electroless Nickel (EN) Coatings

In the present reserch, a model has been proposed for estimate fracture toughness of Nickel-phosphorus (EN) layers. For this purpose, high phosphorus (9%) EN coatings with thicknesses of 6, 12, 24, 36 and 48 urn were applied on steel substrates and then treated as conventional process. Fracture toughness of coatings was obtained using Vickers indentation method. It is found that fracture toughness increses as coating thickness reduces. Effect of coating thickness on fracture toughness was exhibited by various models. Evaluation of models revealed good agreement between of proposed model (Kc=f(t,t2)) and experimental data.

Experimental investigations on small-and full-scale ship models with polyurea coatings subjected to underwater explosion

Nowadays, the mitigation of damage to a ship caused by the underwater explosion attracts more and more attention from the modern ship designers. In this study, two kinds of scale tests were conducted to investigate the effects of polyurea coatings on the blast resistance of hulls subjected to underwater explosion. Firstly, small-scale model tests with different polyurea coatings were carried out. Results indicate that polyurea has a better blast resistance performance when coated on the front face, which can effectively reduce the maximum deflection of the steel plate by more than 20% and reduce the deformation energy by 35.7%-45.4%. Next, a full-scale ship(approximately 50 m × 9 m) under loadings produced by the detonation of 33 kg of spherical TNT charges was tested, where a part of the ship was coated with polyurea on the front face(8 mm + 24 mm) and not on the contrast area. Damage characteristics on the bottom were statistically analyzed based on a 3D scanning technology, indicating that polyurea contributes to enhancing the blast protection of the ship. However, damage results of this test were different from those of the small-scale tests. Moreover, the deformation area of the bottom with polyurea was greatly increased by 40.1% to disperse explosion energy, a conclusion that cannot be drown from the small-scale tests.

An interface shear damage model of chromium coating/steel substrate under thermal erosion load

The Cr-plated coating inside a gun barrel can effectively improve the barrel’s erosion resistance and thus increase the service life.However,due to the cyclic thermal load caused by high-temperature gunpowder,micro-element damage tends to occur within the Cr coating/steel substrate interface,leading to a gradual deterioration in macro-mechanical properties for the material in the related region.In order to mimic this cyclic thermal load and,thereby,study the thermal erosion behavior of the Cr coating on the barrel’s inner wall,a laser emitter is utilized in the current study.With the help of in-situ tensile test and finite element simulation results,a shear stress distribution law of the Cr coating/steel substrate and a change law of the interface ultimate shear strength are identified.Studies have shown that the Cr coating/steel substrate interface’s ultimate shear strength has a significant weakening effect due to increasing temperature.In this study,the interfacial ultimate shear strength decreases from 2.57 GPa(no erosion)to 1.02 GPa(laser power is 160 W).The data from this experiment is employed to establish a Cr coating/steel substrate interface shear damage model.And this model is used to predict the flaking process of Cr coating by finite element method.The simulation results show that the increase of coating crack spacing and coating thickness will increase the service life of gun barrel.

Three-Component Model for Bidirectional Reflection Distribution Function of Thermal Coating Surfaces

We present a bidirectional reflection distribution function （BRDF） model for thermal coating surfaces based on a three-component reflection assumption, in which the specular reflection is given according to the microfacet theory and Snell＇s law, the multiple reflection is considered Nth cosine distributed, and the volume scattering is uniformly distributed in reflection angles according to the experimental results. This model describes the reflection characteristics of thermal coating surfaces more completely and reasonably. Simulation and measurement results of two thermal coating samples SR107 and S781 are given to validate that this three-component model significantly improves the modeling accuracy for thermal coating surfaces compared with the existing BRDF models.

Exact Solutions of a Power Law Fluid Model in Posttreatment Analysis of Wire Coating with Linearly Varying Boundary Temperature

In this paper, analysis of post-treatment of wire coating is presented. Coating material satisfies power law fluid model. Exact solutions for the velocity field, volume flow rate and average velocity are obtained. Moreover, the heat transfer results are presented for different cases of linearly varying on the boundaries. The variations of velocity, volume flow rate, radius of coated wire, shear rate and the force on the total wire are presented graphically and discussed.

亚麻纤维热解动力学的“model free”法和Coats-Redfern模型拟合法研究

亚麻纤维是一种潜在的气化原料,本文对亚麻纤维的热解行为进行了热重分析研究。10mg粒径为0.60~0.85mm的亚麻纤维颗粒在高纯氮气的保护下分别以10、20、30、50K.min-1的升温速率线性升温到550℃。使用＂model free＂方法和Coats-Redfern模型拟合方法分析亚麻纤维的热解过程,并估算出热解反应的表观活化能。本文中＂model free＂方法包括Friedman、Flynn-wall-Ozawa、Vyazovkin and Wight三种等转化率方法及Kissinger法。三种等转化率方法均得到活化能随着转化率的升高而升高的规律。四种＂model free＂方法显示亚麻纤维的活化能主要在155~175kJ·mol-1之间,使用模型拟合方法所获得亚麻纤维热解反应的活化能值在175kJ·mol-1左右,使用模型拟合方法和＂model free＂方法所得的活化能值接近。这些活化能值可以为亚麻纤维高效的热化学利用提供基础数据。

Preparation and characterization of molybdenum powders with copper coating by the electroless plating technique

Molybdenum powders with a diameter of approximately 3 μn were coated with copper using the electroless plating technique in the pH 12.5-13 and temperature range of 55-75℃. The optimization of the electroless copper bath was evaluated through the combination of process parameters like pH and temperature. The optimized values ofpH and temperature were found to be 12.5 and 60℃, respectively, which attributes to the bright maroon color of the coating with an increase in weight of 46%. The uncoated and coated powders were subjected to microstructural studies using scanning electron microscope （SEM） and the phases were analyzed using X-my diffrction （XRD）. An attempt was made to understand the growth mechanism of the coating. The diffusion-shrinkage autocatalytic model was suggested for copper growth on the molybdenum surface.

Heat Transfer during the Solidification of Hot Dip Aluminizing Coating

Hot dip aluminizing is one of the most effective methods of surface protection for steels and is gradually gaining popularity.Although the pulling speed is one of the most important parameters to control the coating thickness of aluminizing products,however,there are few publications on the mathematical modeling of pulling speed during the hot dip process.In order to describe the correlation among the pulling speed,coating thickness and solidification time,the principle of mass and heat transfer during the aluminizing process is investigated in this paper.The mathematical models are based on Navier-Stokes equation and heat transfer analysis.Experiments using the self-designed equipment are carried out to validate the mathematical models.Specifically,aluminum melt is purified at 730 ℃.The Cook-Norteman method is used for the pretreatment of Q235 steel plates.The temperature of hot dip aluminizing is set to 690 ℃ and thedipping time is set to 3 min.A direct current motor with stepless speed variation is used to adjust the pulling speed.The temperature change of the coating is recorded by an infrared thermometer,and the coating thickness is measured by using image analysis.The validate experiment results indicate that the coating thickness is proportional to the square root of pulling speed for the Q235 steel plate,and that there is a linear relationship between coating thickness and solidification time when the pulling speed is lower than 0.11 m/s.The prediction of the proposed model fits well with the experimental observations of the coating thickness.

Kinetic Study of SiO_2/S Coating Deposition by APCVD

To alleviate catalytic coking on the inner surface of radiant tube for ethylene production in petrochemical plants,SiO2/S coatings were deposited on HP40 alloy specimens using dimethyldisulfide （DMDS） and tetraethoxysilane （TEOS） by atmospheric pressure chemical vapor deposition （APCVD）. A two-dimension mathematical model was made to predict the growth rate of SiO2/S coating and to study the effects of deposition parameters on the deposition rate. The results show that the predicted deposition rate is in good agreement with the experimental one. The deposition rate mainly depends on the concentrations of precursors in the total gas flow, concentrations of intermediates on the deposition surface, total gas flow rate and deposition temperature. The weight of SiO2/S coating linearly increases with the deposition time. When the gas flow rate is below 0.3 m/s, the rate-limiting step of SiO2/S coating deposition is the diffusions of intermediates.However, the surface reactions of intermediates will be the rate-limiting step after the gas flow rate is above 0.3 m/s. When the deposition temperature is below 780℃, the rate-limiting step of SiO2/S coating deposition mainly depends on the surface reactions of intermediates. When the deposition temperature is above 780℃,the rate-limiting step depends on the diffusions of intermediates. The deposition rate increases with increasing the concentrations of the intermediates. However, when the partial pressures of the intermediates reach 8 Pa,the deposition rate keeps constant.

A review of TRISO-coated particle nuclear fuel performance models

The success of high temperature gas cooled reactor depends upon the safety and quality of the coated particle fuel. The understanding and evaluation of this fuel requires the development of an integrated mechanistic fuel performance model that fully describes the mechanical and physicochemical behavior of the fuel particle under irradiation. In this paper, a review of the analytical capability of some of the existing computer codes for coated particle fuel was performed. These existing models and codes include FZJ model, JAERI model, Stress3 model, ATLAS model, PARFUME model and TIMCOAT model. The theoretic model, methodology, calculation parameters and benchmark of these codes were classified. Based on the failure mechanism of coated particle, the advantage and limits of the models were compared and discussed. The calculated results of the coated particles for China HTR-10 by using some existing code are shown. Finally, problems and challenges in fuel performance modeling were listed.

Storage life prediction under pre-strained thermally-accelerated aging of HTPB coating using the change of crosslinking density

In order to predict the storage life of a certain type of HTPB(hydroyl-terminated polybutadiene)coating at 25℃ and analyze the influence of pre-strain on the storage life,the accelerated aging tests of HTPB coating at 40℃,50℃,60℃,70℃ with the pre-strain of 0%,3%,6%,9%,respectively were carried out.The variation regularity of the change of crosslinking density was analyzed and the aging model of HTPB coating under pre-strained thermally-accelerated aging was proposed.The storage life of HTPB coating at 25℃ was estimated by using the Berthelot equation as the end point of the aging life with a 30% decrease in maximum elongation.The results showed that the change of crosslinking density of HTPB coating increased with the increase of aging temperature and aging time,and decreased with the increase of pre-strain.Under 0% prestrain,the relationship between the change of crosslinking density of HTPB coating and the aging time can be described by the logarithmic model with the confidence probability greater than 99%.The stress relaxation phenomenon existed under 3%,6%and 9%pre-strained aging.The aging model considering chemical aging and pre-strain was established with the confidence probability greater than 90%.The storage life of HTPB coating was 15.2935 years at 25C under 0% prestrain,which was reduced by 13.9007%,75.6949% and 89.7859% under 3%,6% and 9% pre-strain,respectively.The existence of pre-strain has a serious impact on the storage life of HTPB coating,therefore,the pre-strain should be avoided as much as possible during the actual storage.

Multiscale Characterization of Automotive Surface Coating Formation for Sustainable Manufacturing

汽车的表面涂层生产是在汽车的汇编的最复杂、昂贵的步之一。这步涉及通过油漆水花在车辆表面上产生聚合涂层的多重薄层并且在多级式的、动态地变化的环境治好。传统地，质量管理是基于的完全过程以后的检查，并且处理运作的调整仅仅经验被基于，这样生产不能是(高度) 持续。在这篇文章，当模特儿的一个多尺度的系统和分析方法论为通过在汽车的表面涂层生产治好的油漆水花和电影完成聚合材料的持续应用被介绍。由这方法论，在油漆材料之中的关联，应用程序进程和涂层，性能能被识别。基于模型的分析在大量长度和时间允许材料，进程，和产品的动态行为的全面、深的研究。案例研究为持续生产说明方法论的功效。

Experimental and finite element analysis for fracture of coating layer of galvannealed steel sheet

Mechanical properties of galvannealed (GA) steel sheet used for automotive exposed panel and predicted failure phenomenon of its coating layer were evaluated using finite element method. V-bending test was performed to understand better the fracture of coating layer of GA steel sheet during plastic deformation. Yield strength of the coating layer was calculated by using a relative difference between hardness of coating layer measured from the nano-indentation test and that of substrate. To measure shearing strength at the interface between substrate and coating layer, shearing test with two specimens attached by an adhesive was carried out. Using the mechanical properties measured, a series of finite element analyses coupled with a failure model was performed. Results reveal that the fracture of coating layer occurs in an irregular manner at the region where compressive deformation is dominant. Meanwhile, a series of vertical cracks perpendicular to material surface are observed at the tensile stressed-region. It is found that 0.26-0.28 of local equivalent plastic strain exists at the coating and substrate at the beginning of failure. The fracture of coating layer depends on ductility of the coating layer considerably as well.

Alginate/gelatin/boron-doped hydroxyapatite-coated Ti implants:in vitro and in vivo evaluation of osseointegration

In this study,boron-doped hydroxyapatite(BHT)-loaded alginate/gelatin-based(A/G)hydrogel coating on Ti was fabricated to support bone integration through triggering osteoinduction,vascularization and immunomodulation.Initially,highly reproducible,cheap and time-effective BHT was produced,which significantly promoted higher osteogenic and angiogenic maturation,while a mild innate immune response was observed.The immense potential of BHT was evidenced by the production of a gap-filling A/G/BHT interphase on Ti implants to mimic the osseous extracellular matrix to achieve functional bridging and exert control over the course of innate immune response.We initially aminosilanized the implant surface using 3-aminopropyl triethoxysilane,and then coated it with 0.25%w/v alginate with 20 mM 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide and N-hydroxysuccinimide to allowthe A/G/BHT pre-gel to disperse evenly and covalently attach on the surface.The pre-gel was added with 0.2 M NaCl to homogeneously blend BHT in the structure without inducing ionic crosslinking.Then,the coated implants were freeze-dried and stored.The coated layer demonstrated high cohesive and adhesive strength,and 8-month-long shelf-life at room temperature and normal humidity.The A/G/BHT was able to coat an irregularly shaped Ti implant.Osteoblasts and endothelial cells thrived on the A/G/BHT,and it demonstrated greatly improved osteogenic and angiogenic capacity.Moreover,A/G/BHT maintained macrophage viability and generated an acute increase in immune response that could be resolved rapidly.Finally,A/G/BHT was shown to induce the robust integration of implant in a rabbit femur osteochondral model within 2months.Therefore,we concluded that A/G/BHT coatings could serve as amultifunctional reservoir,promoting the strong and rapid osseointegration of metallic implants.

Erosion wear behaviour and mechanism of abradable seal coating

The erosion wear behaviour and mechanism of several middle temperature seal coatings were investigated by a CMS 100 self made vacuum sand erosion machine. The results show that the relationship between the erosion mass loss and the erosion time is linear, the coatings hold a maximum erosion rate at 60° impact angle, and the relationship between the erosion rate and the impact speed is an exponential function. The speed exponent increases with the increase of the impact angle. At 90° impact, indentations and extruded lips were generated on the coating surface subjected to impact. With repetitive impact by the abrasive particles, the extruded lips were work hardened and peeled off, while flattened metal phase grains were impacted repeatedly, loosed and debonded. At 30° impact, the erosion wear of the coating is characterized by micro cutting, plowing and tunneling via pores and non metal phase. The model of the erosion mechanism is advanced on the basis of the above mentioned erosion wear behaviour.

Computation of deformation-induced textures in electrodeposited nickel coating

The deformation-induced textures in electrodeposited nickel coating were numerically studied. The finite element method (FEM) for polycrystalline was developed based on Taylor model. Then the deformation-induced textures in electrodeposited nickel coating with initial random and lamellar texture were simulated under tensile load. It is found that the initial textures significantly influence the deformation-induced textures. For nickel coating with the initial random textures, when the tensile strain is about 40%, there are some lamellar textures. For nickel coating with the initial lamellar textures, the lamellar texture is more intensity with the increase of the tensile strain. With the increase of the tensile strain in the coating, there are more pronounced element distortion and a more inhomogeneous deformation. Due to the different crystal orientations, the grain-scale roughness is observed. With increasing tensile strain in the coating, the surface grain-scale roughness increases on the free surface. The surface roughness of the coating with initial random texture is lower than that with the initial lamellar texture.