Simulation of the thermal history and induced mechanical stresses during a plasma spray coating process

International audienceThe aim of this investigation is to combine a thermo mechanical modeling with the growing of coated material by spraying process. A numerical model has been built to describe the thermal history of a plasma spray coating. In this model the freezing of the crushed droplet (splats) by quenching and cooling creates mechanical stresses. These stresses involved cracks in the coating and also unsticking between the coating and the substrate. The practical case of alumina coating on stainless steel substrate is considered. This model tries to forecast these phenomena to put forward possible control. The 2D axisymmetrical model is based on finite element formulation. Results are compared with 1D available result and the interest of 2D extension is underlined in the present study