To study the effect of coating thickness on the erosion process, the
other erosion conditions such as the particle diameter and erodent
velocity are maintained as stated in the description to Fig. 3. The
eroded surface topographies of the substrate material at different
coating thickness (from 40 μm to 120 μm) are represent in Fig. 4.
As seen from Fig. 4, coating damage is serious when the coating
layer thickness is thinner. A conclusion can be drawn that substrate
influence can be eliminated for relatively thick coatings. In order to
analyze the stress variation in the coating and substrate interface,
the article selects the interface element no. 4608 for analysis. It is
noticeable from Fig. 5 that the value of maximum effective strain is
almost to zero at about 100 μm. At this time, the basic matrix is not
destroyed. Combining with Fig. 6, it can be seen that the effective
stress levels are quite high, exceeding the tensile strength of
known coating materials. In addition, a plateau in stress level is observed
when the coating thickness is thicker (about 120 μm in the
example provided).
The simulation is qualitatively in accordance with the coating
performance observed experimentally [27,28]. Nowadays, the average
thickness of C-33 metal-ceramic coating that is widely used in
high-power gas turbines is about 120–150 μm [29]. This confirms
the accuracy of the model. Hence, the reasonable coating thickness
can effectively prevent its peeling.
To study the effect of coating thickness on the erosion process, theother erosion conditions such as the particle diameter and erodentvelocity are maintained as stated in the description to Fig. 3. Theeroded surface topographies of the substrate material at differentcoating thickness (from 40 μm to 120 μm) are represent in Fig. 4.As seen from Fig. 4, coating damage is serious when the coatinglayer thickness is thinner. A conclusion can be drawn that substrateinfluence can be eliminated for relatively thick coatings. In order toanalyze the stress variation in the coating and substrate interface,the article selects the interface element no. 4608 for analysis. It isnoticeable from Fig. 5 that the value of maximum effective strain isalmost to zero at about 100 μm. At this time, the basic matrix is notdestroyed. Combining with Fig. 6, it can be seen that the effectivestress levels are quite high, exceeding the tensile strength ofknown coating materials. In addition, a plateau in stress level is observedwhen the coating thickness is thicker (about 120 μm in theexample provided).The simulation is qualitatively in accordance with the coatingperformance observed experimentally [27,28]. Nowadays, the averagethickness of C-33 metal-ceramic coating that is widely used inhigh-power gas turbines is about 120–150 μm [29]. This confirmsthe accuracy of the model. Hence, the reasonable coating thicknesscan effectively prevent its peeling.
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