Effect of substrate variables on the interface fracture energy of thermal spray coatings

IF 5.3 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology Pub Date : 2025-05-04 DOI:10.1016/j.surfcoat.2025.132237

Saim Abbas , Sanjay Sampath , Sudhanshu Mallick , B. Nagamani Jaya

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引用次数: 0

Abstract

The effects of substrate material, substrate roughness and substrate thickness on the interface fracture energy (G_C) of thermal spray coating/metallic substrate interfaces are determined. Air Plasma Sprayed (APS) coatings of Yttria Stabilized Zirconia (YSZ) and Alumina, as well as NiCrAlY are investigated with different substrate materials (stainless steel-SS, mild steel-MS), roughness and thickness. Modified cantilever beam bending with Digital Image Correlation (DIC) based tracking of crack length is used for high-throughput measurements. A 46 % increase in G_C is seen due to an increase of 73 % substrate roughness (R_a) of substrate for YSZ/SS, while a 60 % increase in G_C is seen due to an increase in 166 % R_a of substrate for Alumina/MS system. Interface fracture energy G_C of YSZ/MS is found to be ∼75 J/m², compared to ∼50 J/m² for the Alumina/MS for similar coating/substrate thickness as well as substrate roughness. For the same coating type and thickness of YSZ, G_C decreased to 60 J/m² when the substrate was changed to SS, even with an increase in R_a. This could be attributed to the significant effect of residual stress, originating from thermal expansion mismatch, with higher compressive residual stresses increasing the propensity for interfacial delamination. There is no effect of substrate thickness on G_C, independent of whether the substrate is machined before or after the deposition. Mechanisms of these changes are discussed in the context of total interface fracture area and crack closure stresses.

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基体变量对热喷涂涂层界面断裂能的影响

确定了基体材料、基体粗糙度和基体厚度对热喷涂涂层/金属基体界面断裂能（GC）的影响。采用不同的基体材料（不锈钢- ss、低碳钢- ms）、粗糙度和厚度，研究了氧化钇稳定氧化锆（YSZ）、氧化铝和NiCrAlY的空气等离子喷涂（APS）涂层。改进悬臂梁弯曲与数字图像相关（DIC）为基础的裂纹长度跟踪用于高通量测量。由于YSZ/SS的基体粗糙度（Ra）增加了73%，GC增加了46%，而氧化铝/质谱系统的基体Ra增加了166%，GC增加了60%。发现YSZ/MS的界面断裂能GC为~ 75 J/m2，而氧化铝/MS的界面断裂能GC为~ 50 J/m2，涂层/衬底厚度和衬底粗糙度相似。对于相同涂层类型和厚度的YSZ，当基体改为SS时，即使Ra增加，GC也下降到60 J/m2。这可能是由于热膨胀失配引起的残余应力的显著影响，较高的压残余应力增加了界面分层的倾向。衬底厚度对GC没有影响，与衬底是在沉积之前还是之后加工无关。从界面总断裂面积和裂纹闭合应力的角度讨论了这些变化的机理。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Surface & Coatings Technology 工程技术-材料科学：膜

CiteScore

10.00

自引率

11.10%

发文量

921

审稿时长

19 days

期刊介绍： Surface and Coatings Technology is an international archival journal publishing scientific papers on significant developments in surface and interface engineering to modify and improve the surface properties of materials for protection in demanding contact conditions or aggressive environments, or for enhanced functional performance. Contributions range from original scientific articles concerned with fundamental and applied aspects of research or direct applications of metallic, inorganic, organic and composite coatings, to invited reviews of current technology in specific areas. Papers submitted to this journal are expected to be in line with the following aspects in processes, and properties/performance: A. Processes: Physical and chemical vapour deposition techniques, thermal and plasma spraying, surface modification by directed energy techniques such as ion, electron and laser beams, thermo-chemical treatment, wet chemical and electrochemical processes such as plating, sol-gel coating, anodization, plasma electrolytic oxidation, etc., but excluding painting. B. Properties/performance: friction performance, wear resistance (e.g., abrasion, erosion, fretting, etc), corrosion and oxidation resistance, thermal protection, diffusion resistance, hydrophilicity/hydrophobicity, and properties relevant to smart materials behaviour and enhanced multifunctional performance for environmental, energy and medical applications, but excluding device aspects.