Development of Algorithm for Calculating the Remaining Life of Thermal Spray Coating

Author Name(s): Ainar R. Ibragimov, Lenar N. Shafigullin, Azat T. Gabdrakhmanov
Author Email: ibragimov.a.r@mail.ru

Abstract

In today’s world, the product lifecycle monitoring technology has become widely used as it enables collection of data bulk and online processing. Therefore, it ensures the efficient use of monitored products and cost saving due to prevention of accidents, failures and other consequences.These investigations also involved thermal spray coatings. The previous papers mostly dealt with the investigations of the mechanical properties of coatings and addressed the spraying modes to improve them. This paper describes the operating principle of the software to calculate the remaining life of thermal spray coatings based on the knowledge about their accumulation and degradation limits.It used the results of 4-point bending tests at different loads as data. During the cycling tests the rate of plastic deformation accumulation was calculated, the math model was made, and the software is based on this model. As a result of these complex studies on 4-point bending, software was developed with an algorithm for calculating the residual life of the gas-thermal coating. It allows you to predict the performance of coatings depending on the calculation of various loads.

Introduction

Investigations of thermal spray coatings are widely spread due to the extensive use of these coatings in various manufacturing sectors, mainly in aircraft engine production, oil and gas industry and machine building. Thermal spray coatings are used for thermal protection, corrosion protection, reinforcement and other functions. In the aircraft industry the coatings are used for blades, atomizers of combustion chambers, jackets of gas turbine engines, 85% of the components have protection coatings [1]. The components with thermal spray coatings operate at a temperature of about 1000 degrees.That’s why there is a great need for these investigations, but the existing methods for determining mechanical properties provide little information, for example, they do not take into account the stresses embedded during plasma spraying. However, these stresses affect adhesive and cohesive bonds in multilayered coatings, increase along with a thickness, and influence the bond strength as well as some other properties [2-5].

Conclusion

Based on the results of comprehensive 4-point bending investigations, the software with the algorithm for calculation the remaining life of thermal spray coatings was designed to predict its durability depending on loads on the coating.

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