Cracked elastic substrate strip with functionally graded coating under thermal-mechanical loading

This paper investigates the functionally graded coating bonded to an elastic strip with a crack under thermal- mechanical loading. Considering some new boundary conditions, it is assumed that the temperature drop across the crack surface is the result of the thermal conductivity index which controls heat conduction through the crack region. By the Fourier transforms, the thermal-elastic mixed boundary value problems are reduced to a system of singular integral equations which can be approximately solved by applying the Chebyshev polynomials. The numerical computation methods for the temperature, the displacement field and the thermal stress intensity factors （TSIFs） are presented. The normal temperature distributions （NTD） with different parameters along the crack surface are analyzed by numerical examples. The influence of the crack position and the thermal-elastic non- homogeneous parameters on the TSIFs of modes I and 11 at the crack tip is presented. Results show that the variation of the thickness of the graded coating has a significant effect on the temperature jump across the crack surfaces when keeping the thickness of the substrate constant, and the thickness of functionally graded material （FGM） coating has a significant effect on the crack in the substrate. The results can be expected to be used for the purpose of gaining better understanding of the thermal-mechanical behavior of graded coatings.

Preparation of Ti6Al4V/BG/HA graded coating by electrophoresis deposition in absolute alcohol medium

A codeposition of bioglass (BG) and hydroxyapatite (HA) on the substrate Ti6Al4V is realized in a nonaqueous solution system by inducing crystallization of HA on surface of the BG grain and electrophoresis deposition (EPD), and then a bioactive graded ceramic coating was obtained after sintering of the coating. This technique is a new method for making bioactive graded coating. The adhesive strength between the coating and the substrate reaches 18?MPa, and the better electrophoresis depositing parameters and optimal sintering procedure are obtained.

A facile method for fabrication of nano-structured Ni-Al_2O_3 graded coatings: Structural characterization

Powder charges of micron-size Ni and Al2O3were utilized to deposit nano-structured Ni-Al2O3composite coatings on analuminum plate fixed at the top end of a milling vial using a planetary ball mill.Composite coatings were fabricated using powdermixtures with a wide range of Ni/Al2O3mass ratio varying from1:1to plain Ni.XRD,SEM and TEM techniques were employed tostudy the structural characteristics of the coatings.It was found that the composition of the starting mixture strongly affects the Al2O3content and the microstructure of the final coating.Mixtures containing higher contents of Al2O3yield higher volume fractions of theAl2O3particles in the coating.Though Ni-Al2O3composite coatings with about50%of Al2O3particles were successfully deposited,well-compacted and free of cracks and/or voids coatings included less than20%(volume fraction)of Al2O3particles which weredeposited from powder mixtures with Ni/Al2O3mass ratios of4:1or higher.Moreover,mechanical and metallurgical bondings arethe main mechanisms of the adhesion of the coating to the Al substrate.Finally,functionally graded composite coatings withnoticeable compaction and integrity were produced by deposition of two separate layers under identical coating conditions.

Bonding strength of graded anti-corrosive coatings of fluoroethylenepropylene (FEP)/polyphenylene sulfide (PPS)

Fluororesin-based anti-corrosive coatings including graded FEP/PPS were prepared on carbon steel by melt powder coating, the bonding strength of all coating systems was determined by the pull-off test. It is found that the poor adhesion of fluororesin coatings to metallic substrates is improved obviously by the graded coating structure of FEP/PPS, and the bonding strength reaches up to 11.8 MPa for the five-layer system. Examination by electron probe microanalysis （EPMA） verifies that the distribution of main components is graded in the five-layer system, which is responsible for the enhancement of the interfacial bonding.

Cracking in orthotropic half-plane with a functionally graded coating under anti-plane loading

This investigation evaluates, by the dislocation method, the dynamic stress intensity factors of cracked orthotropic half-plane and functionally graded material coating of a coating- substrate material due to the action of anti-plane traction on the crack surfaces. First, by using the complex Fourier transform, the dislocation problem can be solved and the stress fields are obtained with Cauchy singularity at the location of dislocation. The dislocation solution is utilized to derive integral equations for multiple interacting cracks in the orthotropic half-plane with functionally graded orthotropic coating. Several examples are solved and dynamic stress intensity factors are obtained.

Characterization of functionally graded ZrO_2 thermal barrier coatings sprayed by supersonic plasma spray with dual powder feed ports

The functionally graded thermal barrier coatings （FG-TBCs） with 80%ZrO2-13%CeO2-7%Y2O3 （C-YSZ）/NiCoCrAlY were prepared using a recently developed supersonic plasma spraying（S-PS） with dual powder feed ports system. The thermal shock experiment of FG-TBCs specimens was carried out by means of the automatic thermal cycle device, in which the samples were heated to 1200℃ by oxygen-acetylene flame jet then water-quenched to ambient temperature. The temperature—time curves of specimens and photographs can be watched on-line and recorded by a computer during the test. The results show that the totally 1mm-thick FG-TBCs have excellent thermal shock resistance due to the fact that the coatings have no any peeling-off after 200 thermal cycles. The microstructures and morphologies of FG-TBCs were characterized and analyzed by SEM.

Characterization of Failure Mechanisms of Duplex and Graded Thermal Barrier Coatings Exposed to Thermal Shock Test

The beginning of failure of a (ZrO2-7%Y2O3)/(Ni-22%Co-17%Cr-12.5%Al-0.6%Y) duplex andgraded coating systems on lnconel 617 and IN738LC in burner rig tests has been characterized.The test conditions are 40 s heating up to 75O℃ substrate temperature followed by 80 s aircooling. Failure is considered at the appearance of the first bright spot during heating period.Stresses due to thermal expansion mismatch strains on cooling are the probable cause of life-limiting in this conditions of testing.

Thermal Residual Stresses in Multilayered Coatings

The mechanical integrity and reliability of coated devices are strongly affected by the residual stresses in thin films and coatings. However, due to the metallurgical complexity of materials, it is rather difficult to obtain a closed-form solution of residual stresses within multilayered coatings （e.g. functionally graded coatings, FGCs）. In this paper,an analytical model is developed to predict the distribution of residual stresses within multilayered coatings. The advantage of this model is that the solution of residual stresses is independent of the number of layers. Specific results are obtained by calculating elastic thermal stresses in ZrO2/NiCoCrAIY FGCs, which consist of different material layers. Furthermore, the residual stress distribution near the edges and the stress-induced failure modes of coating are also analyzed. The topics discussed provide some insights into the development of a methodology for designing fail-safe coating systems.

Co-electrodeposition and properties evaluation of functionally gradient nickel coated ZrO_2 composite coating

For the first time,functionally electroless nickel plated ZrO2(NCZ)graded Ni-NCZ composite coating has been successfully co-electrodeposited from a bath with gradually increasing of stirring rate.Studies showed that co-electrodeposition in a bath with stirring rate of250r/min results in the maximum co-electrodeposited particle content and the best particle distribution.To produce NCZ graded Ni-NCZ composite coating,the stirring rate was continuously increased from0to250r/min.The electroplated coating had a continuous gradient increasing of co-electrodeposited NCZ content from substrate towards the surface.The results showed that with increasing the co-electrodeposited NCZ particles content in Ni matrix,microhardness increases from interface towards the surface of the coating.Little crystallite size of Ni matrix and higher co-electrodeposited hard particles content were recognized as the reasons of microhardness increasing.Bend test revealed that the functionally graded composite coating shows more excellent adhesion to the substrate compared with the ordinary distributed Ni-NCZ on the same substrate.This result is attributed to lower mechanical mismatch between coating and substrate in the functionally graded composite coating with respect to the uniformly distributed one.The results of wear resistance measurements reveal that wear resistance of functionally graded Ni-NCZ is higher than that of ordinary distributed composite coating.