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Mechanical characterization and impact damage assessment of Al/SiC functionally graded coating under elevated
D Muniraj1, S Vignesh1, V M Sreehari2
1School of Mechanical Engineering, SASTRA Deemed University, Thanjavur, 613401, Tamilnadu, India.
Scientific Reports
|November 25, 2024
Summary
Functionally graded plasma spray coatings (FGPS) on aluminum substrates were studied for impact dynamics and damage behavior at varying temperatures. Higher temperatures reduced impact forces and rebound velocity, indicating potential for improved material design.
Area of Science:
- Materials Science
- Mechanical Engineering
- Composite Materials
Background:
- Functionally graded materials (FGMs) offer tailored properties for demanding applications in aerospace, defense, and automotive industries.
- Plasma spray coatings are utilized to enhance surface properties of substrates, but their performance under dynamic loading and varying temperatures requires detailed investigation.
Purpose of the Study:
- To investigate the impact dynamics and damage behavior of functionally graded plasma spray coatings (FGPS) on an aluminum 6061-T6 substrate.
- To analyze the effect of various temperatures on the high-velocity impact response of FGPS.
Main Methods:
- Experiments were conducted using a single-stage gas gun with a thermal setup, applying 260 J impact energy to FGPS samples at different temperatures.
- A finite element model was developed incorporating the Johnson-Cook damage model and piecewise linear plasticity with appropriate contact algorithms for simulation.
- Micro-morphological studies were performed to analyze the coating's bonding and porosity.
Main Results:
- Impact simulations showed that increased temperature leads to reduced stiffness, resulting in lower peak contact force, decreased rebound velocity, and increased central deflection.
- Micro-morphological analysis revealed molten splats spread over several micrometers, indicating excellent particle bonding.
- The porosity content of the FGPS was measured to be 1.35%.
Conclusions:
- The study provides critical insights into the impact dynamics and damage mechanisms of FGPS under thermal and impact loading.
- Findings suggest that temperature significantly influences the mechanical response of FGPS, with higher temperatures mitigating impact effects.
- The excellent bonding and low porosity observed highlight the potential of FGPS for applications requiring high performance under dynamic conditions.
