Simulation of the thermo-mechanical behavior and residual stresses in the spray coating process

In order to be able to forecast the thermo-mechanical behavior and the residual stress in the spray coating process, a continuum mecromechanical model for describing the interaction involving temperature, the solidifying mode and, the stress/strain curve is developed in this paper. A set of coupled equations of the heat conduction, stress/strain and solidification is given by the metallo-thermo-mechanical theory. For this simulation, a numerical modeling based on the finite element method for calculating the heat conduction associated with solidification and the stresses at the interface between multi-layer materials is proposed. Here, the temperature field, the solidified state and the residual stresses of the spray coating process, including interfacial combinations between substrate and sprayed layer, are presented, and the validity of the calculated results is discussed in comparison with experimental X-ray results. (C) 1999 Elsevier Science S.A. All rights reserved.