Experimental Measurement of Residual Stress on Thermal Spray Coatings with Moire Interferometry and Hole-Drilling Method

Abstract:

Residual stress is one of the important factors in thermally sprayed deposits which affects both processing and performances. In the present study, the hole-drilling method and moire interferometry were used to determine the residual stress of thermally sprayed coatings to overcome certain limitations of the strain rosette version of hole drilling. The methodology was established based on the elastic theory and finite element method. The residual displacement was measured by moire interferometry and the residual stress of the thermally sprayed coating was calculated. The results have demonstrated that moire interferometry for surface displacement caused by hole-drilling is high sensitive, reliable and stable.

• Periodical: Applied Mechanics and Materials (Volume 782)
• Pages: 335-340
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.782.335
• Online since: August 2015
• Authors: Jian Guo Zhu, Bao Ge Zhang
• Keywords: Experimental Measurement, Moiré Interferometry, Residual Stress, Thermal Barrier Coatings

References

[1] A.G. Evans, D.R. Mumm, J.W. Hutchinson, G.H. Meier F.S. Pettit, Mechanisms controlling the durability of thermal barrier coatings. Prog. Mater Sci., 46 (2001) 505-553.

DOI: 10.1016/s0079-6425(00)00020-7

[2] A. Rabiei, A.G. Evans, Failure mechanisms associated with the thermally grown oxide in plasma-sprayed thermal barrier coatings. Acta Mater., 48 (2000) 3963-3976.

DOI: 10.1016/s1359-6454(00)00171-3

[3] J. Matejicek, S. Sampath, P.C. Brand, H.J. Prask, Quenching, thermal and residual stress in plasma sprayed deposits: NiCrAlY and YSZ coatings. Acta Mater., 47 (1999) 607-617.

DOI: 10.1016/s1359-6454(98)00360-7

[4] J. Matejicek, S. Sampath, Intrinsic residual stresses in single splats produced by thermal spray processes. Acta Mater., 49 (2001) 1993-(1999).

DOI: 10.1016/s1359-6454(01)00099-4

[5] O. Kesler, M. Finot, S. Suresh, S. Sampath, Determination of processing-induced stresses and properties of layered and graded coatings: Experimental method and results for plasma-sprayed Ni--Al2O3. Acta Mater., 45 (1997) 3123-3134.

DOI: 10.1016/s1359-6454(97)00015-3

[6] J. Matejicek, S. Sampath, In situ measurement of residual stresses and elastic moduli in thermal sprayed coatings - Part 1: apparatus and analysis. Acta Mater., 51 (2003) 863-872.

DOI: 10.1016/s1359-6454(02)00478-0

[7] T. Clyne, S. Gill, Residual Stresses in Thermal Spray Coatings and Their Effect on Interfacial Adhesion: A Review of Recent Work. J. Therm. Spray Technol., 5 (1996) 401-418.

DOI: 10.1007/bf02645271

[8] M. Wenzelburger, D. López, R. Gadow, Methods and application of residual stress analysis on thermally sprayed coatings and layer composites. Surf. Coat. Tech., 201 (2006) 1995-(2001).

DOI: 10.1016/j.surfcoat.2006.04.040

[9] G.G. Stoney, , The Tension of Metallic Films Deposited by Electrolysis. Proc. R. Soc. London Ser. A82 (1909) 172-175.

[10] Y.C. Tsui, T.W. Clyne, An analytical model for predicting residual stresses in progressively deposited coatings Part 1: Planar geometry. Thin Solid Films, 306 (1997) 23-33.

DOI: 10.1016/s0040-6090(97)00199-5

[11] Y.Y. Hu, W.M. Huang, Elastic and elastic-plastic analysis of multilayer thin films: Closed-form solutions. J. Appl. Phys., 96 (2004) 4154-4160.

DOI: 10.1063/1.1786339

[12] A. Makino, D. Nelson, Residual-stress determination by single-axis holographic interferometry and hole drilling—Part I: Theory. Exp. Mech., 34 (1994) 66-78.

DOI: 10.1007/bf02328443

[13] D.V. Nelson, A. Makino, T. Schmidt, Residual stress determination using hole drilling and 3D image correlation. Exp. Mech., 46 (2006) 31-38.

DOI: 10.1007/s11340-006-5859-0

[14] Z.Q. Guo, H.M. Xie, B. Liu, F.L. Dai, P.W. Chen, Q.M. Zhang, F.L. Huang, Study on deformation of polycrystalline aluminum alloy using moiré interferometry. Exp. Mech., 46 (2006) 699-711.

DOI: 10.1007/s11340-006-9823-9