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Residual Stresses Distribution through Thick HVOF Sprayed Inconel 718 Coatings

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An Erratum to this article was published on 10 December 2008

Abstract

Residual stress buildup in thick thermal spray coatings is a property of concern. The adhesion of these coatings to the substrate is influenced by residual stresses that are generated during the coating deposition process. In the HVOF spray process, significant peening stresses are generated during the impact of semimolten particles on the substrate. The combination of these peening stresses together with quenching and thermal mismatch stresses that arise after deposition can be of significant importance. Both numerical method, i.e., Finite Element Method (FEM), and experimental methods, i.e., the Modified Layer Removal Method (MLRM) and Neutron Diffraction, to calculate peening and quenching stresses have been utilized in this work. The investigation was performed on thick Inconel 718 coatings on Inconel 718 substrates. Combined, these numerical and experimental techniques yield a deeper understanding of residual stress formation in the HVOF process and thus a tool for process optimization. The relationship between the stress state and deposit/substrate thickness ratio is given particular interest.

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Acknowledgments

The authors acknowledge the financial support of the VINNOVA (Swedish Governmental Agency for Innovation Systems) funded NFFP project and the technical support of the Thermal Spray Department of Volvo Aero Corporation (Trollhättan, Sweden). The research project has been supported by the EC under the 6th Framework Programme through the Key Action: Strengthening the European Research Area, Research Infrastructures. Contract no.: RII3-CT-2003-505925 (NMI3). The authors would like to thank Dr. R. Wympory and Dr. D.J. Hughes for their respective collaboration to carry out Neutron Diffraction measurement at the Hahn-Meitner Institute (Berlin) and at the Laue-Langevin Institute (Grenoble). Particular acknowledgments are addressed to Kjell Niklasson of University West (Trollhättan) for supervision in the FEA simulations.

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Authors and Affiliations

  1. University West, Trollhättan, Sweden

    C. Lyphout & P. Nylén

  2. Università Politecnica delle Marche, Ancona, Italy

    A. Manescu

  3. Laue-Langevin Institute (ILL), Grenoble, France

    T. Pirling

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  1. C. Lyphout
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  2. P. Nylén
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  3. A. Manescu
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  4. T. Pirling
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Correspondence to C. Lyphout.

Additional information

An erratum to this article can be found at http://dx.doi.org/10.1007/s11666-008-9289-7

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Lyphout, C., Nylén, P., Manescu, A. et al. Residual Stresses Distribution through Thick HVOF Sprayed Inconel 718 Coatings. J Therm Spray Tech 17, 915–923 (2008). https://doi.org/10.1007/s11666-008-9242-9

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