skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: The effect of residual stresses on the debonding of coatings; 2: An experimental study of a thermally sprayed system

Abstract

Specimens have been produced by plasma spraying of boron carbide coatings about 1 mm in thickness on to titanium alloy substrates about 3 mm thick. The residual stress distributions in these specimens have been calculated using a numerical process model and also estimated from observed changes in curvature on debonding. Good agreement as observed between the two methods, with both suggesting the average substrate stress to be about +20 MPa and the average coating stress to be about [minus]60 MPa. In both constituents, there was a significant positive gradient of stress level through the thickness. These specimens were loaded in four point bending until cracks propagated along the interface between substrate and coating. From the load/displacement plots obtained during this testing, and taking account of the effect of relaxation of the residual stresses during debonding, the critical strain energy release rates of the interfaces, G[sub ic], were estimated to be [approximately] 0.2--0.5 kJ m[sup [minus]2]. Substantial errors would have resulted from neglect of the presence of the residual stresses. Also of significance is the effect of the residual stresses on the mode mixity of interfacial loading, as characterized by the phase angle, [psi], since G[sub ic] has been often observedmore » to vary with [psi]. The value of [psi] for the four point bend test in the absence of residual stress is about 47[degree], whereas for the specimens tested here it was estimated to cover the complete range from 90[degree] (pure shear) to 0[degree] (pure opening) as the applied load was increased. The quoted values of G[sub ic] were obtained in a regime where [psi] [approximately] 30[degree].« less

Authors:
; ;  [1]
  1. Univ. of Cambridge (United Kingdom). Dept. of Materials Science and Metallurgy
Publication Date:
OSTI Identifier:
7180825
Resource Type:
Journal Article
Journal Name:
Acta Metallurgica et Materialia; (United States)
Additional Journal Information:
Journal Volume: 42:8; Journal ID: ISSN 0956-7151
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; METALS; SPRAYED COATINGS; ADHESION; RESIDUAL STRESSES; COMPOSITE MATERIALS; DEFECTS; INTERFACES; MATHEMATICAL MODELS; STRESS INTENSITY FACTORS; COATINGS; ELEMENTS; MATERIALS; STRESSES; 360603* - Materials- Properties

Citation Formats

Tsui, Y C, Howard, S J, and Clyne, T W. The effect of residual stresses on the debonding of coatings; 2: An experimental study of a thermally sprayed system. United States: N. p., 1994. Web. doi:10.1016/0956-7151(94)90224-0.
Tsui, Y C, Howard, S J, & Clyne, T W. The effect of residual stresses on the debonding of coatings; 2: An experimental study of a thermally sprayed system. United States. https://doi.org/10.1016/0956-7151(94)90224-0
Tsui, Y C, Howard, S J, and Clyne, T W. 1994. "The effect of residual stresses on the debonding of coatings; 2: An experimental study of a thermally sprayed system". United States. https://doi.org/10.1016/0956-7151(94)90224-0.
@article{osti_7180825,
title = {The effect of residual stresses on the debonding of coatings; 2: An experimental study of a thermally sprayed system},
author = {Tsui, Y C and Howard, S J and Clyne, T W},
abstractNote = {Specimens have been produced by plasma spraying of boron carbide coatings about 1 mm in thickness on to titanium alloy substrates about 3 mm thick. The residual stress distributions in these specimens have been calculated using a numerical process model and also estimated from observed changes in curvature on debonding. Good agreement as observed between the two methods, with both suggesting the average substrate stress to be about +20 MPa and the average coating stress to be about [minus]60 MPa. In both constituents, there was a significant positive gradient of stress level through the thickness. These specimens were loaded in four point bending until cracks propagated along the interface between substrate and coating. From the load/displacement plots obtained during this testing, and taking account of the effect of relaxation of the residual stresses during debonding, the critical strain energy release rates of the interfaces, G[sub ic], were estimated to be [approximately] 0.2--0.5 kJ m[sup [minus]2]. Substantial errors would have resulted from neglect of the presence of the residual stresses. Also of significance is the effect of the residual stresses on the mode mixity of interfacial loading, as characterized by the phase angle, [psi], since G[sub ic] has been often observed to vary with [psi]. The value of [psi] for the four point bend test in the absence of residual stress is about 47[degree], whereas for the specimens tested here it was estimated to cover the complete range from 90[degree] (pure shear) to 0[degree] (pure opening) as the applied load was increased. The quoted values of G[sub ic] were obtained in a regime where [psi] [approximately] 30[degree].},
doi = {10.1016/0956-7151(94)90224-0},
url = {https://www.osti.gov/biblio/7180825}, journal = {Acta Metallurgica et Materialia; (United States)},
issn = {0956-7151},
number = ,
volume = 42:8,
place = {United States},
year = {1994},
month = {8}
}