Skip to content
Licensed Unlicensed Requires Authentication Published by De Gruyter December 22, 2014

Residual Stress Analysis of Thick Film Systems by the Incremental Hole-Drilling Method*

Influence of Interlayers and Interfacial Roughness
E. Held and J. Gibmeier

Abstract

Residual stresses play an important role in coating systems as they determine their properties as well as their life-time behavior. In many industrial applications multi-layer systems are used. This work examines the applicability of the incremental hole drilling method to determine residual stress states in multi-layer coating systems, i.e. in the top-layer, in the interlayer and in the substrate. For this purpose systematic finite element (FE) simulations are carried out. Initially, the interfaces were assumed to be planar and subsequently rough interfaces were considered. The results indicate that thin interlayers with layer thicknesses smaller than 30 μm can be neglected in the evaluation of the measured strain relaxations, since they lead only to a minor stress deviation. In case of larger interlayer thicknesses a case-specific calibration, taking into account the exact build-up of the multilayer system, results in reliable determinations of the residual stress states, in the top-layer, the interlayer and the substrate. Finally the simulation results are applied to a model thick film system consisting of a thermally sprayed Al2O3-coating on a fine-grained construction steel (S690QL). Its residual stress state is determined experimentally by the incremental hole-drilling method.

Kurzfassung

Eigenspannungen spielen in Schichtverbunden für deren Eigenschaften und deren Lebensdauerverhalten eine entscheidende Rolle. In vielen Anwendungen werden mehrschichtige Verbunde eingesetzt. Diese Arbeit untersucht die Anwendbarkeit der inkrementellen Bohrlochmethode zur Bestimmung von Eigenspannungstiefenverläufen auf Mehrschichtverbunde, d. h. sowohl in der Deckschicht als auch in der Zwischenschicht und im darunterliegenden Substrat. Hierfür werden systematische Finite-Elemente (FE)-Simulationen durchgeführt. Es wird zunächst von einer ebenen Grenzschicht ausgegangen. Im Anschluss werden ebenfalls raue Grenzschichten betrachtet. Es kann gezeigt werden, dass dünne Zwischenschichten mit Schichtdicken kleiner als 30 μm bei der Auswertung der Dehnungsauslösung vernachlässigt werden können und nur geringfügige Abweichungen bei den berechneten Eigenspannungsverteilungen resultieren. Bei größeren Zwischenschichtdicken führt eine fallspezifische Kalibrierung unter Berücksichtigung des genauen Schichtaufbaus zu zuverlässigen Eigenspannungstiefenverläufen in der Deckschicht, in der Zwischenschicht und im darunterliegenden Substrat. Schlussendlich werden die Simulationsergebnisse experimentell auf ein Modellschichtsystem, bestehend aus einer thermisch gespritzten Al2O3-Schicht auf einem Feinkornbaustahl (S690QL), angewendet.


2 (Corresponding author/Kontakt)
*

Enhanced contribution based upon a presentation at the International Conference on Residual Stresses ICRS9, October 7–9, 2012, in Garmisch-Partenkirchen, Germany


References

1. Vaßen, R.; Jarligo, M. O.; Steinke, T.; Mack, D. E.; Stöver, D.: Overview on advanced thermal barrier coatings. Surf. Coatings Technol.205 (2010) 4, pp. 938942, 10.1016/j.surfcoat.2010.08.151Search in Google Scholar

2. König, G.: Ein Beitrag zur Weiterentwicklung teilzerstörender Eigenspannungsmeßverfahren. MPA Stuttgart, Techn.-wiss. Berichte, Heft 91–02Search in Google Scholar

3. Schwarz, T.; Kockelmann, H.: Die Bohrlochmethode – ein für viele Anwendungsbereiche optimales Verfahren zur experimentellen Ermittlung von Eigenspannungen. Messtechn. Briefe29 (1993), pp. 3338Search in Google Scholar

4. Schajer, G. S.: Measurement of Non-uniform Residual Stresses Using the Hole-Drilling Method. Part I: Stress Calculation Procedures. J. Eng. Mater. Technol.110 (1988), pp. 338343, 10.1115/1.3226059Search in Google Scholar

5. Schajer, G. S.: Measurement of Non-uniform Residual Stresses Using the Hole-Drilling Method. Part II: Practical Application of the Integral Method. J. Eng. Mater. Technol.110 (1988), pp. 344349, 10.1115/1.3226060Search in Google Scholar

6. Obelode, E.; Gibmeier, J.: Residual Stress Analysis on Thick Film Systems by the Incremental Hole-Drilling Method – Simulation and Experimental Results. Exp. Mech.53 (2013) 6, pp. 965976, 10.1007/s11340-013-9720-ySearch in Google Scholar

7. Wenzelburger, M.; López, D.; Gadow, R.: Methods and application of residual stress analysis on thermally sprayed coatings and layer composites. Surf. Coatings Technol.201 (2006) 5, pp. 19952001, 10.1016/j.surfcoat.2006.04.040Search in Google Scholar

8. Santana, Y. Y.; La Barbera-Sosa, J. G.; Staia, M. H.; Lesage, J.; Puchi-Cabrera, E. S.; Chicot, D.; Bemporad, E.: Measurement of residual stress in thermal spray coatings by the incremental hole drilling method. Surf. Coatings Technol.201 (2006) 5, pp. 20922098, 10.1016/j.surfcoat.2006.04.056Search in Google Scholar

9. Buchmann, M.; Gadow, R.; Tabellion, J.: Experimental and numerical residual stress analysis of layer coated composites. Mater. Sci. Eng.288 (2000) 2, pp. 154159, 10.1016/S0921-5093(00)00862-5Search in Google Scholar

10. Obelode, E.; Gibmeier, J.: Influence of the interfacial roughness on residual stress analysis of thick film systems by incremental hole drilling. Material Science Forum768–769 (2014), pp. 136143, 10.1016/s0921-5093(00)00862-5Search in Google Scholar

11. Montay, G.; Cherouat, A.; Lu, J.; Baradel, N.; Bianchi, L.: Development of the high-precision incremental-step hole-drilling method for the study of residual stress in multi-layer materials: influence of temperature and substrate on ZrO2-Y2O3 8 wt.% coatings. Surf. Coatings Technol.155 (2002) 2–3, pp. 152160, 10.1016/s0257-8972(01)01718-2Search in Google Scholar

12. Hauk, V. M.; Oudelhoven, R. W. M.; Vaessen, G. J. H.: The state of residual stress in the near surface region of homogeneous and heterogeneous materials after grinding. Met. Trans.13 (1982) 7, pp. 12391244, 10.1007/bf02645507Search in Google Scholar

13. Standard ASTM E837-08: Test Method for Determining Residual Stresses by Hole-Drilling Strain-Gage Method. ASTM, Materials Park, 2008, 10.1520/e0837-08Search in Google Scholar

14. Pawlowski, L.: The Science and Engineering of Thermal Spray Coatings. John Wiley & Sons, Inc., UK, 2008, 10.1002/9780470754085Search in Google Scholar

Published Online: 2014-12-22
Published in Print: 2014-04-30

© 2014, Carl Hanser Verlag, München

Scroll Up Arrow