Skip to main content
SpringerLink
Log in

Residual Stress Analysis on Thick Film Systems by the Incremental Hole-Drilling Method – Simulation and Experimental Results

  • Published:
Experimental Mechanics Aims and scope Submit manuscript

Abstract

The residual stress state in thick film systems, as for example thermal spray coatings, is crucial for many of the component’s properties and for the evaluation of the integrity of the coating under thermal and/or mechanical loading. Therefore it is necessary to be able to determine the local residual stress distribution in the coating, at the interface and in the substrate. The incremental hole-drilling method is a widely used method for measuring residual stress depth profiles, which was already applied for thermally sprayed coatings. But so far no reliable hole-drilling evaluation method exists for layered materials having a stress gradient in depth. The objective was to investigate, how far existing evaluation methods of the incremental hole-drilling method that are only valid for residual stress analysis of homogenous material states can be applied to thick film systems with coating thicknesses between 50 μm and 1000 μm and to point out the application limits for these already existing methods. A systematic Finite Element (FE) study was carried out for coating systems with an axisymmetric residual stress state σ1 = σ2. It is shown that conventional evaluation methods developed for homogeneous, non-layered material states can be successfully applied for a stress evaluation in the substrate and the coating for small and for sufficiently large coating thicknesses, respectively, regardless of the type of evaluation algorithm used i.e. the differential or the integral method. The same accounts for material combinations that have a Young’s modulus ratio close to one, between 0.8 and 1.2. The studies indicated that outside the given ranges case specific calibration must be applied to calculate reliable results. Further, calibration data were determined case specifically for a selected model coating system. The accuracy of a residual stress determination using these case specific calibration data was examined and the sensitivity of the evaluation with respect to an accurate knowledge of the boundary conditions of the coating system i.e. the coating thickness and the Young modulus was studied systematically. Finally, the calibration data were applied on a thermally sprayed aluminium coating on a steel substrate analysis and the results for using the incremental hole drilling method were compared to results from X-ray stress analysis.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

References

  1. Griffiths BJ, Gawne DT, Dong G (1996) The erosion of steel surfaces by grit-blasting as a preparation for plasma spraying. Wear 194(1–2):95–102

    Article  Google Scholar 

  2. Griffiths BJ, Gawne DT, Dong G (1997) The role of grit blasting in the production of high-adhesion plasma sprayed alumina coatings. Proc IME B J Eng Manufact 211(1):1–9

    Article  Google Scholar 

  3. Kuroda S, Clyne TW (1991) The quenching stress in thermally sprayed coatings. Thin Solid Films 200(1):49–66

    Article  Google Scholar 

  4. Kuroda S, Fukushima T, Kitahara S (1990) Generation mechanisms of residual stresses in plasma-sprayed coatings. Vacuum 41(4–6):1297–1299

    Article  Google Scholar 

  5. He MY, Evans AG, Hutchinson JW (2000) The ratcheting of compressed thermally grown thin films on ductile substrates. Acta Materialia 48(10):2593–2601

    Article  Google Scholar 

  6. Clyne TW, Gill SC (1996) Residual stresses in thermal spray coatings and their effect on interfacial adhesion: a review of recent work. J Therm Spray Technol 5(4):401–418

    Article  Google Scholar 

  7. Perry AJ, Sue JA, Martin PJ (1996) Practical measurement of the residual stress in coatings. Surf Coat Technol 81(1):17–28

    Article  Google Scholar 

  8. Wenzelburger M, López D, Gadow R (2006) Methods and application of residual stress analysis on thermally sprayed coatings and layer composites. Surf Coat Technol 201(5):1995–2001

    Article  Google Scholar 

  9. Macherauch E, Müller P (1961) Das sin2ψ-verfahren der röntgenographischen spannungsmessung. Z angew Physik 13:340–345

    Google Scholar 

  10. Eigenmann B, Macherauch E (1995) Röntgenographische Untersuchung von Spannungszuständen in Werkstoffen. Mater Werkst 26(3):148–160

    Article  Google Scholar 

  11. Moore MG, Evans WP (1958) Mathematical correction for stress in removed layers in X-Ray diffraction residual stress analysis. SAE Trans 66:340–345

    Google Scholar 

  12. ASTM E837-08. Standard Test Method for Determining Residual Stresses by Hole-Drilling Strain-Gage method

  13. Santana YY, La Barbera-Sosa JG, Staia MH, et al. (2006) Measurement of residual stress in thermal spray coatings by the incremental hole drilling method. Surf. Coat. Technol. 201(5):2092–2098

    Google Scholar 

  14. Valente T, Bartuli C, Sebastiani M, Loreto A (2005) Implementation and development of the incremental hole drilling method for the measurement of residual stress in thermal spray coatings. J Therm Spray Technol 14:462–470

    Article  Google Scholar 

  15. Buchmann M, Gadow R, Tabellion J (2000) Experimental and numerical residual stress analysis of layer coated composites. Mat Sci Eng A 288(2):154–159

    Article  Google Scholar 

  16. Nelson DV, Makino A, Fuchs EA (1997) The holographic-hole drilling method for residual stress determination. Opt Lasers Eng 27(1):3–23

    Article  Google Scholar 

  17. Schajer G (2010) Advances in hole-drilling residual stress measurements. Exp Mech 50(2):159–168

    Article  Google Scholar 

  18. Schajer G, Steinzig M (2005) Full-field calculation of hole drilling residual stresses from electronic speckle pattern interferometry data. Exp Mech 45(6):526–532

    Article  Google Scholar 

  19. Schwarz T, Kockelmann H (1993) Die Bohrlochmethode - ein für viele Anwendungsbereiche optimales Verfahren zur experimentellen Ermittlung von Eigenspannungen. Messtechnische Briefe 29:33–38

    Google Scholar 

  20. Schajer GS (1988) Measurement of Non-uniform residual stresses using the hole-drilling method. Part I - stress calculation procedures. J Eng Mater Technol 110:338–343

    Article  Google Scholar 

  21. Schajer GS (1988) Measurement of Non-uniform residual stresses using the hole-drilling method. Part II - practical application of the integral method. J Eng Mater Technol 110:344–349

    Article  Google Scholar 

  22. H. Kockelmann, G. König (1987) Ablschlussbericht zum DFG-Forschungsvorhaben Ko 896/2-1 Kennwort: Bohrlochmethode. Stuttgart: Materialprüfanstalt (MPA) Stuttgart;201

  23. König G. Ein Beitrag zur (1991) Weiterentwicklung teilzerstörender Eigenspannungsmeßverfahren. MPA Stuttgart

  24. Moskowitz LN (1993) Application of HVOF thermal spraying to solve corrosion problems in the petroleum industry—an industrial note. J Therm Spray Technol 2(1):21–29

    Article  Google Scholar 

  25. McPherson R (1989) A review of microstructure and properties of plasma sprayed ceramic coatings. Surface and Coatings Technology. 39–40, Part 1(0):173–181

    Google Scholar 

  26. Eigenmann B, Macherauch E (1996) Röntgenographische Untersuchung von Spannungszuständen in Werkstoffen Teil IV. Mater Werkst 27(10):491–501

    Article  Google Scholar 

  27. Eigenmann B, Macherauch E (1996) Röntgenographische Untersuchung von Spannungszuständen in Werkstoffen. Teil III. Mater Werkst 27(9):426–437

    Article  Google Scholar 

  28. DIN EN ISO 14577 Metallic materials - Instrumented indentation test for hardness and materials parameters. In: DIN EN ISO 14577 Metallic materials - Instrumented indentation test for hardness and materials parameters. Berlin: Beuth Verlag

  29. Gibmeier J, Nobre JP, Scholtes B (2004) Residual stress determination by the hole drilling method in the case of highly stressed surface layers. Mater Sci Res Int 10(1):21–25

    Google Scholar 

  30. Gibmeier J, Kornmeier M, Scholtes B (2000) Plastic deformation during application of the hole-drilling method. MSF 347–349:131–137

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Institute for Applied Materials, Karlsruhe Institute for Technology, Engelbert-Arnold-Str. 4, 76131, Karlsruhe, Germany

    E. Obelode & J. Gibmeier

Authors
  1. E. Obelode
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. J. Gibmeier
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to E. Obelode.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Obelode, E., Gibmeier, J. Residual Stress Analysis on Thick Film Systems by the Incremental Hole-Drilling Method – Simulation and Experimental Results. Exp Mech 53, 965–976 (2013). https://doi.org/10.1007/s11340-013-9720-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11340-013-9720-y

Keywords

Search

Navigation