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Experimental and numerical investigation of residual stress in coatings on steel
S. Ojha, J.G. Thakare, A. Giri, , M.M. Mahapatra, R.S. Mulik
Published in ASTM International
Volume: 48
Issue: 6
Pages: 4370 - 4386
In the present work, an alumina–titania (13 %) coating has been deposited by the air plasma spray process on a mild steel substrate by preheating the substrate to different temperatures. Coating thickness was measured by a scanning electron microscope, the hardness of coatings was measured, and morphology was also checked. The crack compliance technique has been used to determine the residual stress, as it is a very simple method, and also, it is compatible with conventional machining equipment and wire electric discharge machining equipment. Specimens were cut by the diamond cutter up to certain depth in microns, and the strain relieved was recorded. For finding out the residual stress, these recorded values of strain have been used by doing a finite element analysis (FEA) using the ANSYS 15.0 (Ansys, Inc., Canonsburg, PA) software. For validation of the model, uniaxial tension was applied on a sample by using the INSTRON universal testing machine (Instron Inc., Norwood, MA), and strain values at both the coating side and the substrate side were recorded and matched with the model under the same value of the load. After verifying the model, an equation has been developed using the Minitab software (Minitab Inc, Bengaluru, India), and the strains previously recorded were used as an input to the equation obtained, and the value of residual stress was calculated. The maximum value of residual stress was found at the coating–substrate interface, and the values of residual stress for sample preheated at 250°C, 200°C, and 150°C were found to be compressive, with the magnitude of −176.28 MPa, −243.54 MPa, and −255.42 MPa, respectively. Copyright © 2019 by ASTM International,
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