Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “BENDING”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,603 records · Page 89
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

The effect of thermomechanical treatment and tempering on the subsurface microstructure and bendability of direct-quenched low-carbon strip steel

Highlights: • Surface properties mainly determine the bendability of high strength steel. • Tempering improves bendability by softening the microstructure. • Surface texture is affected by thermomechanical treatment but not by tempering. • Strong shear texture component and upper bainite are detrimental to bendability. - Abstract: Recent results in the literature have shown that subsurface properties play a key role during the bending of steel plates. Now, for the first time, surface microstructure, surface texture, subsurface hardness and dislocation density have been studied to reveal the effect of tempering and thermomechanical treatment on the bendability of a direct-quenched strip steel. In the experiments, different thermomechanical treatments as well as non-isothermal tempering treatments were performed with slow heating to 570 °C and slow cooling to simulate the tempering of large steel coils in a batch annealing furnace. The results show that in addition to the improved production efficiency obtained through direct quenching and a single tempering process, tempering improves bendability by reducing subsurface dislocation density and hardness without a significant loss of strip yield strength. The subsurface microstructure and texture of the strip are the result of thermo-mechanical processing and transformation behaviour. Upper bainite containing elongated Martensite-Austenite (MA) islands in addition to an intense shear texture component {112}<111>{sub α} leads to shear band formation, and therefore poorer bendability when the bend axis is perpendicular to the rolling direction. This texture is not affected by tempering. Therefore, tempering does not improve the bendability of steels with an unfavourable texture. When the subsurface layers comprise a softer ferritic microstructure, good bendability is obtained in the untempered direct-quenched condition with a modest improvement caused by tempering.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Comparative study of microstructure and properties of low-alloy-steel/nickel-based-alloy interfaces in dissimilar metal weld joints prepared by different GTAW methods

Highlights: • Number of type I and type II boundaries: H-DMWJ > C-DMWJ > W-DMWJ. • Width carbon depleted zones and carbon enriched zones: H-DMWJ > C-DMWJ > W-DMWJ. • Type I and type II boundaries are susceptible to SCC and cracked during mechanical bending. • C-DMWJ has the best performance while H-DMWJ has the worst one. - Abstract: Low-alloy-steel/buttering (or welding) metal interfaces in safe-end dissimilar metal weld joints (DMWJs) at nuclear power plants are weak parts. To optimize the quality of the safe-end DMWJs used for the construction of domestic nuclear power plants and to improve the welding productivity, a series of DMWJs in full-size have been manufactured by using different gas tungsten arc welding (GTAW) methods. The microstructure, chemical composition distribution and local properties across the SA508/52(M) interfaces in these DMWJs are studied. The high heat input and long high temperature duration during hot-wire GTAW process promote the carbon diffusion and grain boundary migration and hence the DMWJ by hot-wire GTAW has the largest amount of type I and type II boundaries and the widest carbon depleted zones and carbon enriched zones, which resulting in the worst performance among the DMWJs in simulated primary water. Type I and type II boundaries are high angle random grain boundaries (RGBs) and Cr-depleted zones are found along type II boundaries resulting in their high susceptibility to SCC. In addition, these boundaries are prone to be cracked during mechanical bending process.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Effect of n-HA content on the isothermal crystallization, morphology and mechanical property of n-HA/PLGA composites

Graphical abstract: Effect of n-HA content on the isothermal crystallization, morphology and mechanical property of n-HA/PLGA composites was studied in details. The results showed that the addition of higher content of g-n-HA was favorable to promote the crystallization better in g-n-HA/PLGA composites, but it could also cause more agglomeration in PLGA matrix, as a result of worse mechanical properties, and the addition content of 3 wt% g-n-HA to PLGA matrix was an appropriate proportion, which had the highest bending strength among these g-n-HA/PLGA composites, and it might be potential to be used in biomedical fields in future. Highlights: ► The effect of n-HA content on the n-HA/PLGA composites was studied in detail. ► Isothermal crystallization, microstructure and mechanical property were studied. ► The relation between n-HA content and properties of n-HA/PLGA composite was found. ► An appropriate proportion of n-HA in n-HA/PLGA composite was obtained. - Abstract: A serials of g-n-HA/PLGA composites with surface-modified g-n-HA of 1%, 3%, 6%, 10% and 15% in weight were prepared by solution mixing. The isothermal crystallization, morphology and mechanical property of g-n-HA/PLGA composites were investigated by differential scanning calorimeter (DSC), scanning electron microscope (SEM) and electromechanical universal tester. The results showed that Avrami equation was suitable for describing the isothermal crystallization process in this system, and the crystallization rate of g-n-HA/PLGA composites containing more than 3 wt% g-n-HA was basically accord with the relational expression of T{sub 110} {sub °C} > T{sub 105°C} > T{sub 115°C} > T{sub 120°C}. Moreover, at the same Tc, crystallization rate was greatly enhanced with the increasing of g-n-HA acting as nucleate. However, the addition of higher content of g-n-HA would cause more agglomeration in PLGA matrix, so that the mechanical properties of g-n-HA/PLGA composites would gradually decrease. In conclusion, the addition of higher content of g-n-HA was favorable to promote the crystallization better in g-n-HA/PLGA composites, but it could also cause more agglomeration in PLGA matrix, result in worse mechanical properties, and the addition content of 3 wt% g-n-HA to PLGA matrix was an appropriate proportion, which had the highest bending strength among these g-n-HA/PLGA composites, and it might be potential to be used in biomedical fields in future.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Degradation behavior of hydroxyapatite/poly(lactic-co-glycolic) acid nanocomposite in simulated body fluid

Graphical abstract: In this manuscript, we initiated a systematic study to investigate the effect of HA on thermal properties, inner structure, reduction of mechanical strength, surface morphology and the surface deposit of n-HA/PLGA composite with respect to the soaking time. The results showed that n-HA played an important role in improving the degradation behavior of n-HA/PLGA composite, which can accelerate the degradation of n-HA/PLGA composite and endow it with bioactivity, after n-HA was detached from PLGA during the degradation, so that n-HA/PLGA composite may have a more promising prospect of the clinical application than pure PLGA as bone fracture internal fixation materials, and the results would be of reference significance to predict the in vivo degradation and biological properties. - Highlights: • Effect of n-HA on degradation behavior of n-HA/PLGA composite was investigated. • Degradation behaviors of n-HA/PLGA and PLGA were carried out in SBF for 6 months. • Viscosity, thermal properties, inner structure and bending strength were tested. • n-HA can accelerate the degradation and endows it with bioactivity. - Abstract: To investigate the effect of hydroxyapatite(HA) on the degradation behavior of hydroxyapatite/poly(lactic-co-glycolic) acid (HA/PLGA) nanocomposite, the degradation experiment of n-HA/PLGA composite and pure PLGA were carried out by soaking in simulated body fluid(SBF) at 37 °C for 1, 2, 4 and 6 months. The change of intrinsic viscosity, thermal properties, inner structure, bending strength reduction, surface morphology and the surface deposit of n-HA/PLGA composite and pure PLGA with respect to the soaking time were investigated by means of UbbeloHde Viscometer, differential scanning calorimeter (DSC), scanning electron microscope(SEM), electromechanical universal tester, a conventional camera and X-ray diffraction (XRD). The results showed that n-HA played an important role in improving the degradation behavior of n-HA/PLGA composite, which can accelerate the degradation PLGA and endow it with bioactivity, after n-HA was detached from PLGA during the degradation, so that n-HA/PLGA composite may have a more promising prospect of the clinical application than pure PLGA as bone fracture internal fixation materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Deformation and Delamination of Dynamically Bulging Bilayered Films

We employ finite element simulations to study the dynamic bulging of films under shock tube conditions and compare these responses with quasi-static bulging. Both scenarios subject the film to time-varying pressure. Two film types are considered: uniform material films and bilayers with a relatively soft interior layer and a hard exterior layer. The interface between the materials in the bilayer cases is modeled as a cohesive zone that follows a bilinear normal traction-separation cohesive law. Additionally, bilayer films with preexisting cracks in the interior layer are analyzed. Parametric studies are also conducted to explore the effects of loading rate and specimen size. The mechanical response of all materials is assumed to be strain-rate independent, focusing solely on the inertial effects in the response of the films under dynamic loading, and the absence of such effects under quasi-static loading. The results indicate that quasi-static bulging exhibits a predictable plate bending like deformation. In contrast, depending on the loading rate and specimen size, dynamic bulging can give rise to elastic waves, and a sequence of deformation processes including initial uniform acceleration, followed by bending-like deformation, and finally through-thickness biaxial stretching. Dynamic loading also leads to larger bulge formation and greater deformation than quasi-static loading. A key finding is the role of preexisting cracks in driving delamination under dynamic loading, which is absent in quasi-static loading. This work enhances our understanding of dynamic bulging and motivates further research on characterizing delamination in layered films using dynamic bulge tests.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Shear induced weakening of the hydrogen bonding lattice of the energetic material 5,5'-Hydrazinebistetrazole at high-pressure

5,5'-Hydrazinebistetrazole (HBTA) has been studied by in-situ x-ray diffraction and vibrational spectroscopy to pressures near 25 GPa at room temperature. Analysis of the x-ray diffraction pattern of HBTA collected at ambient pressure and temperature revealed a monoclinic structure consistent with that previously reported. Under compression, the x-ray diffraction reveals little evidence of a phase transition over the pressure range studied. Slight anisotropy in response to compression was noted and the β angle decreased moderately, suggesting geometry modifications occur in the hydrogen bonding lattice and between neighboring HBTA molecules as a result of compression along the c axis. Blue shifts in the Infrared active N-H stretching modes were observed, implying a weakening of the hydrogen bond with compression. The weakening of the hydrogen bonding lattice with pressure may lead to an increase in the bending angle of the C-N=N-C bridge between the tetrazole rings and an increased overlap between the π-bonding orbitals. The Raman spectra showed a number of modes associated with H-N=N-H motions of the bridge become more prominent in the spectra under compression. Additionally, the possibility that the increased bend in the angle of the C-N=N-C bridge results from a shearing deformation is discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

An implantable biomechanical energy harvester for animal monitoring devices

Insufficient service life and the resulting need for battery replacements have been a great challenge for implantable electronic devices. This is particularly true for animal tracking applications, because recapturing animals is often unlikely once they are released to the wild. To tackle this problem, we developed a biomechanical energy harvester that uses a Macro Fiber Composite™ (MFC) piezoelectric beam to harvest the mechanical energy from animals’ body bending movements as the power source for implantable and wearable devices. Prototypes of an underwater acoustic transmitter using this technology were subdermally implanted into juvenile white sturgeon and their energy harvesting performance was evaluated through the device’s transmissions. Additionally, the fish successfully recovered from the implantation surgery and freely swam inside a tank. The transmitter prototypes in the fish continually transmitted signals for a period up to 5 weeks. A benchtop test setup was also created to emulate the fish’s body bending, estimate the device’s energy harvesting performance in the live fish, and perform accelerated fatigue testing of the energy harvester by applying test parameters learned from a video study of the fish’s body movement and behavior characteristics. The gradual depolarization of the piezoelectric ceramic material in the MFC under cyclic mechanical loading was the main limiting factor for the life span of the energy harvester. Pathways for improvement are proposed to achieve long-term efficacy of powering implantable and wearable electronic devices.

42 ENGINEERING↗
DOE OSTI2017

A concept for canceling the leakage field inside the stored beam chamber of a septum magnet

Here, the Advanced Photon Source is in the process of upgrading its storage ring from a double-bend to a multi-bend lattice as part of the APS Upgrade Project (APS-U). A swap-out injection scheme is planned for the APS-U to keep a constant beam current and to enable a small dynamic aperture. A novel concept that cancels out the effect of leakage field inside the stored beam chamber was introduced in the design of the septum magnet. As a result, the horizontal deflecting angle of the stored beam was reduced to below 1 µrad with a 2 mm septum thickness and 1.06 T normal injection field. The concept helped to minimize the integrated skew quadrupole field and normal sextupole fields inside stored beam chamber as well.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2019

Numerical optimization of a low emittance lattice cell

In the lattice designs for the next generation storage ring light sources, longitudinal gradient bending magnets and anti-bending magnets have been adopted. A logical question raised by the trend of varying the longitudinal distribution of dipole strength is: what are the optimal distributions of the dipole and quadrupole fields in a lattice cell for the purpose of minimizing the natural emittance? We studied this problem by numerically optimizing the dipole and quadrupole distributions of the normalized cell optics using the particle swarm optimization algorithm. Furthermore the results reveal the features of the longitudinal field variation of the optimized cell and show that when the quadrupole gradient is increased enough, the cell tends to split into two identical cells with similar features.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Large radial shift experiments in RHIC and their implications for EIC design

The Hadron Storage Ring (HSR) in the future Electron-Ion Collider (EIC) must operate over a broad range of design circumferences. In 2018 preliminary beam studies on the circumference adjustment capabilities of the Relativistic Heavy Ion Collider (RHIC) were performed by applying a small momentum offset to the circulating bunches without adjusting any bending magnets. The off-momentum linear optics were corrected back to on-momentum conditions. Applying a similarly small deviation to the dipole fields of a select set of bending magnets provides a large radial shift over much of the RHIC (or HSR) circumference while leaving the design trajectory unchanged in the insertion regions. Here, this paper presents the design of the different lattice configurations foreseen as the most viable options for the required HSR circumference changes, and highlights the modifications necessary for regular operations and to allow for testing these new settings in RHIC. Experimental results from 2021 and 2022 are reviewed and compared to model predictions obtained from both MAD-X and Bmad. The implications of these results for HSR design are discussed.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Influence of fatigue precracking and specimen size on Master Curve fracture toughness measurements of EUROFER97 and F82H steels

EUROFER97 and F82H steels are two leading reduced-activation ferritic-martensitic (RAFM) steels for fusion first wall and blanket applications. Exposure to the harsh environment of fusion reactors can result in severe degradation of fracture toughness. Thus, the post-irradiation evaluation of fracture toughness is critical for understanding the material behavior. Due to the space constraints of irradiation facilities and challenges in controlling a uniform irradiation condition for large size specimens, the development of small specimen test techniques (SSTT) is indispensable to evaluate the performance of irradiated materials. In this study, we evaluated specimen size effects on the Master Curve fracture toughness of EUROFER97 and F82H steels. A wide variety of specimens, including 0.5 T compact tension (C(T)) specimens, 0.16 T mini-compact tension (miniC(T)) specimens, and 1.65 mm miniature bend bar specimens, were tested. The testing methodology was based on the Master Curve method in the ASTM E1921 standard. No specimen size effect was observed in 0.5 T C(T) and 0.16 T miniC(T) specimens on the Master Curve reference temperature T0, while 1.65 mm miniature bend bar specimens yielded a higher T 0Q . A strong effect of fatigue precracking on T 0 for 0.5 T C(T) and 0.16 T miniC(T) specimens was observed, such that testing on specimens with skewed fatigue precrack fronts resulted in lower T 0 than for specimens with ASTM standard qualified straight fatigue precrack fronts. The results highlight the importance of experimental quality control in developing SSTT for Master Curve fracture toughness testing. Lastly, we also evaluated and provided recommendations on the minimum number of specimens needed for each specimen type for yielding reliable T 0Q values.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Impact of control blade insertion on the deformation behavior of SiC-SiC channel boxes in BWRs

This article describes the analysis of distortion of a silicon carbide fiber-reinforced, silicon carbide matrix (SiC-SiC) composite channel box under in-reactor conditions of a boiling water reactor (BWR). The BWR core has significant gradients in the fast neutron flux across the channel box due to the presence of water rods within the fuel assemblies, and these gradients increase further with the insertion of control blades. As a result of the temperature and neutron flux dependent irradiation-induced swelling of SiC, the SiC-SiC composite channel box can undergo distortion. In this work, we evaluate the SiC-SiC channel box distortion for three different control blade positions. This analysis is based on the neutron flux and temperature distributions in the BWR core calculated using the neutronics code MPACT and thermal-hydraulics code CTF. This calculation is coupled through temperature feedback. Subsequently, we have performed structural analysis based on the calculated neutron flux and temperature distributions to determine the deformation and stress development in the channel box. The structural analysis was performed using the fuel performance modeling code BISON and the commercial finite element analysis software Abaqus. The results indicate that large gradients in fast neutron flux (up to 35–40% across a single axial level) will develop across the channel box. Due to these gradients, the channel box will undergo time-dependent bending for all the control blade positions in the assembly. The time-dependent bowing behavior is dominated by the transient swelling of SiC-SiC material under non-uniform neutron flux, and changes with variation in the control blade position. The bending will cause temporary interference between the channel box and control blade, and the interference is expected to be most severe for the fully inserted control blade position. The developed stresses due to differential swelling in the channel box exceed the proportional limit stress of the material, which may cause matrix microcracking in the channel box. However, the stresses remain below the tensile strength of the material, and therefore, development of a full, through-thickness crack in the channel box is not expected. Finally, further work is recommended to explore and evaluate the mitigation strategies.

42 ENGINEERING↗
DOE OSTI2021

Additive manufacturing of cobalt-based alloy on tool steel by directed energy deposition

Cladding hard-surfacing alloys on tool steel is an effective approach to enhance the surface properties of tool steel. In this study, a Co-based alloy was deposited on tool steel by Directed Energy Deposition (DED) following a three-factor three-level design of experiment matrix with varied laser power, scan speed, and powder flow rate. The microstructure of the deposits was characterized using scanning electron microscopy (SEM). The residual stress on the surface of the samples was measured by the X-ray diffraction (XRD) sin2? technique. The parameters that produced promising deposits were used to fabricate samples for tensile test, four-point bending test, Charpy impact test, and hardness measurement. Our result reveals that the processing parameters have a significant role in the residual stress of the coatings. Residual stress reduces with the increase of laser energy density. Cracks were found at samples with energy density below a threshold. Tensile testing of the coating/substrate combined structure reveals fracture at the coatings with an ultimate tensile strength of 633.9 ± 54.7 MPa. The bi-material interface survived the tensile test, indicating a strong interfacial bond. The four-point bending test of coating/substrate laminates shows an ultimate flexure strength of 860.6 ± 36.9 MPa. Cracks initiated from the coatings ignored the interface and penetrated the substrate, suggesting a solid bi-material bond. Charpy impact test shows the absorbed energy of coating/substrate laminates is more than doubled that of the substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Enhanced outcoupling in flexible organic light-emitting diodes on scattering polyimide substrates

We demonstrate an upscalable approach to increase outcoupling in organic light-emitting diodes (OLEDs) fabricated on flexible substrates. The outcoupling enhancement is enabled by introducing a thin film of microporous polyimide on the backside of silver nanowire (AgNW) electrodes embedded in neat colorless polyimide. This porous polyimide film, prepared by immersion precipitation, utilizes a large index contrast between the polyimide host and randomly distributed air voids, resulting in broadband haze (>75%). In addition, the composite polyimide/AgNW scattering substrate inherits the high thermal (>360 °C), chemical, and mechanical stability of polyimides. The outcoupling efficiency of the composite scattering substrate is studied via optical characterization of the composite substrate and electron microscopy of the scattering film. The flexible scattering substrates compared to glass/indium tin oxide (ITO) allows for a 74% enhancement in external quantum efficiency (EQE) for a phosphorescent green OLED, and 68% EQE enhancement for a phosphorescent white OLED. The outcoupling enhancement remains unharmed after 5000 bending cycles at a 2 mm bending radius. Moreover, the color uniformity over viewing angles is improved, an important feature for lighting applications.

42 ENGINEERING↗
DOE OSTI2016

Membrane tension feedback on shape and motility of eukaryotic cells

In the framework of a phase field model of a single cell crawling on a substrate, we investigate how the properties of the cell membrane affect the shape and motility of the cell. Since the membrane influences the cell dynamics on multiple levels and provides a nontrivial feedback, we consider the following fundamental interactions: (i) the reduction of the actin polymerization rate by membrane tension; (ii) area conservation of the cell’s two-dimensional cross-section vs. conservation of the circumference (i.e. membrane inextensibility); and (iii) the contribution from the membrane’s bending energy to the shape and integrity of the cell. As in experiments, we investigate two pertinent observables — the cell’s velocity and its aspect ratio. We find that the most important effect is the feedback of membrane tension on the actin polymerization. Bending rigidity has only minor effects, visible mostly in dynamic reshaping events, as exemplified by collisions of the cell with an obstacle.

Winkler, Benjamin↗
DOE OSTI2020

Origin of the Tunable Carrier Selectivity of Atomic-Layer-Deposited TiOx Nanolayers in Crystalline Silicon Colar Cells

Titanium oxide (TiOx) nanolayers grown by atomic layer deposition are investigated with respect to their application as carrier selective contacts for crystalline silicon (c-Si) solar cells. Although TiOx is known to act as an electron contact, in this work the selectivity of TiOx layers is found to be widely tunable from electron to hole selective depending on deposition conditions, post-deposition treatments, and work function of the metal electrode used. Using TiOx and an intrinsic hydrogenated amorphous silicon buffer layer, solar cell test structure exhibiting open-circuit voltages (Voc) as high as 720 and 650 mV are shown for electron and hole selective contacts, respectively. Surface photovoltage and capacitance-voltage measurements reveal that carrier selectivity is correlated with the amount of c-Si band bending induced by TiOx, which are governed not only by the effective work function difference at the Si/TiOx interface, but also by the negative fixed charge present in the TiOx layer. This new finding is in contrast to the previous model for carrier transport where selectivity is determined only by the asymmetric band offsets at the Si/contact interface. It highlights the influence of induced band bending to produce carrier depletion/inversion conditions, and the importance of its selectivity effect in a c-Si absorber.

14 SOLAR ENERGY↗
DOE OSTI2023

High-temperature chemical expansion of Pr0.1Ce0.9O2-δ thin films determined by Differential Laser Doppler Vibrometry

The chemical expansion of thin-film praseodymium-cerium oxide solid solutions (Pr 0.1 Ce 0.9 O 2-δ , PCO10) is investigated at temperatures ranging from 500 °C to 800 °C and oxygen activities down to about 10 -22 . Differential Laser Doppler Vibrometry (D-LDV) in combination with periodic electrochemical pumping of oxygen is used to detect very small displacements of the sample surface. With decreasing pumping frequency, the film approaches chemical equilibrium, which is nearly reached at 700 °C below 0.01 Hz. D-LDV enables direct measurement of film thickness changes as well as the bending of the underlying substrates due electrochemically induced lateral mechanical stress. The substrate bending is found to be more than an order of magnitude larger than the film thickness change, increasing the detection limit by the same factor. The thickness change of the thin film is calculated from the measured displacement of the sample surface and compared with directly measured values. Thin-film literature data available for low oxygen activities up to 650 °C agree with our measurements. In addition, the thickness change of the film is determined from the displacement at different sample positions, which validates previous measurements. Finally, thin film chemical expansion is found to be larger by a factor of about 2 than the corresponding bulk value in agreement with predictions from a mechanical model that the out-of-plane expansion of a constrained film is increased.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Fatigue behavior of thermal sprayed WC-CoCr- steel systems: Role of process and deposition parameters

Thermal spray deposited WC-CoCr coatings are extensively used for surface protection of wear prone components in a variety of applications. Although the primary purpose of the coating is wear and corrosion protection, many of the coated components are structural systems (aero landing gear, hydraulic cylinders, drive shafts etc.) and as such experience cyclic loading during service and are potentially prone to fatigue failure. It is of interest to ensure that the coating and the application process does not deleteriously affect the fatigue strength of the parent structural metal. It has long been appreciated that the relative fatigue life of a thermal sprayed component can be affected by the residual stresses arising from coating deposition. The magnitude of these stresses can be managed by torch processing parameters and can also be influenced by deposition effects, particularly the deposition temperature. In this study, the effect of both torch operating parameters (particle states) and deposition conditions (notably substrate temperature) were investigated through rotating bending fatigue studies. The results indicate a strong influence of process parameters on relative fatigue life, including credit or debit to the substrate's fatigue life measured via rotating bend beam studies. Damage progression within the substrate was further explored by stripping the coating off part way through fatigue testing, revealing a delay in the onset of substrate damage with more fatigue resistant coatings but no benefit with coatings with inadequate properties. Finally, the results indicate that compressive residual stress and adequate load bearing capability of the coating (both controlled by torch and deposition parameters) delay onset of substrate damage, enabling fatigue credit of the coated component.

36 MATERIALS SCIENCE↗