Abstract
This paper summarizes the basic results of fatigue testing of bodies with both metallic and ceramic thermally sprayed coatings. Three kinds of ceramic coatings (Al2O3, Cr2O3, and olivine) sprayed with DC plasma under identical conditions were investigated together with metallic Ni-5wt.%Al coatings sprayed by wire arc, DC plasma, and HVOF. The elastic modulus of the deposited coatings was investigated using four point bending and resonance method. Bending fatigue tests at resonance frequency were performed with cantilever beam specimens. The processes taking place during the fatigue test are identified and discussed. The morphology of the fracture surfaces was investigated together with microstructure and porosity of the coatings.
Similar content being viewed by others
References
S. Sampath, R. McCune 2000. Thermal-Spray Processing of Materials, MRS Bull., 25(7), 12–14.
O. Kovářík, J. Bensch, G. Massini, M. Boulos, and X. Fan, Induction Plasma Deposition of Refractory Metal: Processing Parameters Optimization, International Thermal Spray Conference 2007: Global Coating Solution, B.R. Marple, M.M. Hyland, Y.C. Lau, C.J. Li, R.S. Lima, and G. Montavon, Eds., ASM International, Beijing, China, 2007, p. 727-732
A. Vaidya, T. Streibl, L. Li, S. Sampath, O. Kovářík, R. Greenlaw 2005. An Integrated Study of Thermal Spray Process-Structure-Property Correlations: A Case Study for Plasma Sprayed Molybdenum Coatings, Mat. Sci. Eng. A-Struct., 403(1–2), 191–204.
O. Kovářík, J. Siegl, J. Nohava, and P. Chráska 2005. Young’s Modulus and Fatigue Behaviour of Plasma Sprayed Alumina Coatings, J. Therm. Spray Technol., 14(2), 231–238.
S. Sampath, X.Y. Jiang, J. Matejicek, L. Prchlik, A. Kulkarni, and A. Vaidya, 2004. Role of Thermal Spray Processing Method on the Microstructure, Residual Stress and Properties of Coatings: An Integrated Study for Ni-5 wt%Al Bond Coat, Mat. Sci. Eng. A-Struct., 364(1–2), 216–231.
D.M. Zhu, and R.A. Miller, 1998. Investigation of Thermal High Cycle and Low Cycle Fatigue Mechanisms of Thick Thermal Barrier Coatings, Mat. Sci. Eng. A-Struct., 245(2), 212–223.
M.R. Stoudt, R.E. Ricker, and R.C. Cammarata, 2001. The Influence of a Multilayered Metallic Coating on Fatigue Crack Nucleation, Int. J. Fatigue, 23, S215–S223
A. Ibrahim, C.C. Berndt, 1998. The Effect of High-Velocity Oxygen Fuel, Thermally Sprayed WC-Co Coatings on the High-Cycle Fatigue of Aluminium Alloy and Steel, J. Mater. Sci., 33(12), 3095–3100.
R.T.R. McGrann, D.J. Greving, J.R. Shadley, E.F. Rybicki, T.L. Kruecke, and B.E. Bodger, 1998. The Effect of Coating Residual Stress on the Fatigue Life of Thermal Spray-Coated Steel and Aluminum, Surf. Coat. Tech., 109(1–3), 59–64.
A. Ibrahim, and C.C. Berndt, 2007. Fatigue and Deformation of HVOF Sprayed WC-Co Coatings and Hard Chrome Plating, Mat. Sci. Eng. A-Struct., 456(1–2), 114–119.
J. Matejicek, and S. Sampath 2001. Intrinsic Residual Stresses in Single Splats Produced by Thermal Spray Processes, Acta Mater., 49(11), 1993–1999.
O. Kesler, J. Matejicek, S. Sampath, S. Suresh, T. Gnaeupel-Herold, P.C. Brand, and H.J. Prask 1998. Measurement of Residual Stress in Plasma-Sprayed Metallic, Ceramic and Composite Coatings, Mat. Sci. Eng. A-Struct., 257(2), 215–224.
H.T. Lee, J.C. Chen, and J.M. Wang 1993. Thermomechanical Behavior of Metals in Cyclic Loading, J. Mater. Sci., 28(20), 5500–5507.
M.P. Luong 1998. Fatigue Limit Evaluation of Metals Using an Infrared Thermographic Technique, Mech. Mater., 28(1–4), 155–163.
J. Dubský, B. Kolman, and M. Vyšohlíd, Residual Stresses and Young-modulus of Alumina and Chromia Plasma Sprayed Deposits, United Thermal Spray Conference UTSC 99, E. Lugscheider and P.A. Kammer, Eds., D.V.S-Verlag, Düsseldorf, Germany, 1999, p. 659-663
M. Mellali, A. Grimaud, A.C. Leger, P. Fauchais, and J. Lu, (1997). Alumina Grit Blasting Parameters for Surface Preparation in the Plasma Spraying Operation, J. Therm. Spray Technol, 6(2), 217–227
L. Prchlik, and S. Sampath, 2007. Effect of the Microstructure of Thermally Sprayed Coatings on Friction and Wear Response Under Lubricated and Dry Sliding Conditions, Wear, 262(1–2), 11–23.
Acknowledgments
This research has been supported by Czech Science Foundation grant No. 106/05/0483. CTSR of SUNY at Stony Brook is acknowledged for specimen preparation.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Kovářík, O., Siegl, J. & Procházka, Z. Fatigue Behavior of Bodies with Thermally Sprayed Metallic and Ceramic Deposits. J Therm Spray Tech 17, 525–532 (2008). https://doi.org/10.1007/s11666-008-9205-1
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-008-9205-1