A residual stresses numerical simulation and the relevant thermal-mechanical mapping relationship of Fe-based coatings

Abstract

Residual stresses model comprehensively considers the three main sources of residual stress during the coating deposition process: quenching stress, thermal stress and phase transformation-induced stress. With the deposited layer temperature, coating thickness, number of deposited layers and relevant workpiece dimensions as the input, the model can easily calculate the final residual stress distribution in the coating. Moreover, the thermal–mechanical behavior during the coating deposition process was revealed through experimental and theoretical analysis of coatings. The results showed that the coating fabricated within the range of 65.2–122.5 °C have relatively low residual stresses, ensuring relatively high service reliability. Keywords: High-speed electric arc spraying, Residual stress, Coating, Crankshaft, Theoretical analysis