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Use of Functionally Graded Material to Decrease Maximum Temperature of a Coating-Substrate System.

Aleksander Yevtushenko1, Katarzyna Topczewska1, Przemysław Zamojski1

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Area of Science:

  • Materials Science
  • Heat Transfer
  • Mathematical Modeling

Background:

  • Understanding temperature distribution in coated systems is vital for applications like braking systems.
  • Functionally gradient materials (FGMs) offer tailored thermal properties, but their thermal behavior requires precise modeling.
  • Frictional heating during braking generates significant thermal loads that impact material integrity.

Purpose of the Study:

  • To develop a mathematical model for temperature distribution in a functionally gradient material (FGM) coating on a substrate.
  • To analyze the thermal response under constant and time-decreasing heat flux, simulating braking conditions.
  • To compare the thermal performance of FGM coatings with homogeneous coatings.

Main Methods:

  • Proposed a mathematical model for heat conduction in a coated system with an exponentially graded FGM coating.
  • Obtained exact solutions in quadrature for parabolic heat conduction boundary-value problems.
  • Derived asymptotic solutions for small and large Fourier numbers.
  • Performed comparative analysis using ZrO2-Ti-6Al-4V FGM on cast iron versus a homogeneous ZrO2 coating.

Main Results:

  • An exact analytical solution for temperature distribution was derived.
  • Asymptotic solutions were obtained for transient heat transfer scenarios.
  • The study quantified the temperature distribution differences between FGM and homogeneous coatings.
  • The model effectively simulates thermal loads typical of frictional heating during braking.

Conclusions:

  • The developed mathematical model accurately predicts temperature distribution in FGM-coated systems under relevant thermal loads.
  • Functionally gradient materials exhibit distinct thermal behavior compared to homogeneous materials, influencing system performance.
  • The findings are applicable to optimizing material selection and design in high-temperature applications, such as automotive braking systems.