涂层厚度对喷涂层疲劳磨损寿命影响的实验研究

采用等离子喷涂制备了不同厚度的铁基涂层,采用扫描电子显微镜（SEM）表征了涂层内部和结合界面处的微观结构,采用球盘式疲劳磨损试验机分别考察了不同厚度涂层的疲劳磨损行为,采用Weibull分布分析并对比了涂层的疲劳磨损寿命。结果表明：适当地增加喷涂层的厚度可以避免整层分层失效的发生,而从在整体上提升涂层的疲劳磨损寿命。采用有限元分析（FEM）研究了涂层内部的应力分布,发现厚涂层界面剪切应力值不足薄涂层界面剪切应力的二分之一,可见显著降低界面剪切应力是较厚涂层拥有更好疲劳性能的主因。     

The axisymmetric torsional contact problem of a functionally graded piezoelectric coated half-space

In this article, we study the axisymmetric tor-sional contact problem of a half-space coated with func-tionally graded piezoelectric material (FGPM) and subjected to a rigid circular punch. It is found that, along the thick-ness direction, the electromechanical properties of FGPMs change exponentially. We apply the Hankel integral trans-form technique and reduce the problem to a singular integral equation, and then numerically determine the unknown con-tact stress and electric displacement at the contact surface. The results show that the surface contact stress, surface azimuthal displacement, surface electric displacement, and inner electromechanical field are obviously dependent on the gradient index of the FGPM coating. It is found that we can adjust the gradient index of the FGPM coating to modify the distributions of the electric displacement and contact stress.     

Fracture mechanics analysis of thin coatings under plane-strain indentation

A combined experimental/analytical work is carried out to elucidate the fracture resistance of a thin, hard coating bonded to a semi-infinite substrate due to indentation by a cylindrical surface. The bending of the coating under the softer substrate induces concentrated tensile stress regions at the lower and upper surfaces of the coating, from which cracks may ensue. The evolution of such damage in a model transparent system (glass/polycarbonate) is viewed in situ from below and from the side of the specimen. The critical load needed to initiate a crack on the lower coating surface generally increase proportionally to the coatings thickness, d. An interesting departure from this trend occurs for thin coatings, where the fracture load, although marred by a large scatter, increases somewhat with decreasing d. The fracture data for the upper coating surface are limited to relatively thick coatings due to the recurrence of premature failure from the coating edges. The behavior in this range is similar to that for the lower surface crack, albeit with an order of magnitude greater fracture resistance.A fracture mechanics analysis in conjunction with FEM is performed to elucidate the stress intensity factors responsible for crack propagation. A crack normal to the coating surface is assumed to emanate either from the lower or upper surface of the coating. A major feature of the solution is the occurrence of a bending-induced compression stress field over a region ahead of the crack tip. This effect, which become more dominant as the ratio between the contact length and the coating thickness is increased, tends to delay the onset of crack propagation, especially for the lower surface crack. Consequently, in applications associated with large indenters, thin and/or tough coatings and stiff substrates, cracking from the upper coating surface may precede that from the lower surface. An interesting feature of this crack shielding mechanism is that when the coating surface contains a distribution of flaws rather than a single crack, small flaws in this population may be more detrimental than large ones. Incorporation of these aspects into the analysis leads to a good correlation with the test results. In the special case of line loading, which constitutes a lower bound for the critical loads, a closed-form, approximate solution for the stress intensity factors or the critical loads are obtained.Plane-strain indentation, although less common than spherical indentation, allows for characterizing the fracture resistance of opaque films through observation from the specimen edge. This approach is not easily implemented to thin films (i.e., less than about a hundred microns), however.     

Stress Analysis for an Elastic Semispace with Surface and Graded Layer Coatings under Induced Torsion

In this paper, the axisymmetric torsional problem of a coating structure consisting of a surface coating, a functionally graded layer and a substrate under a rigid cylindrical punch is investigated. The coating and substrate are homogeneous materials with distinct physical properties while the intermediate layer is inhomogeneous with its shear modulus changing exponentially along the thickness direction. The Hankel integral transform technique is employed to reduce the torsional problem to a singular integral equation with a Cauchy kernel. The circumferential shear stress and displacement fields in the coating structure are calculated by solving the integral equation numerically. The results show that the stiffness ratio has significant effect on the distribution of the circumferential stress and displacement at the interface.     

Conformal contact between layered foundations and punches

We study the contact interaction between rigid punches and viscoelastic foundations with thin coatings for the cases in which the punch and coating surfaces are conformal (mutually repeating). Such problems can arise, for example, when the punch immerses into a solidificating coating before its complete solidification; as a result, the surface takes the shape of the punch base. Examples of such coatings can be a layer of glue, concrete at its young age, many polymeric materials. We consider plane contact problems for inhomogeneous aging viscoelastic basements in the case of their conformal contact with rigid punches. We present the statements of the problems and derive their basic mixed integral equation. The solution of this equation is constructed by using the generalized projection method. We present numerical computations of model problems, including the problem in which the shape of the punch base is described by a rapidly oscillating function.     

Two kinds of contact problems in three-dimensional icosahedral quasicrystals

Two kinds of contact problems, i.e., the frictional contact problem and the adhesive contact problem, in three-dimensional(3D) icosahedral quasicrystals are discussed by a complex variable function method. For the frictional contact problem, the contact stress exhibits power singularities at the edge of the contact zone. For the adhesive contact problem, the contact stress exhibits oscillatory singularities at the edge of the contact zone. The numerical examples show that for the two kinds of contact problems, the contact stress exhibits singularities, and reaches the maximum value at the edge of the contact zone. The phonon-phason coupling constant has a significant effect on the contact stress intensity, while has little impact on the contact stress distribution regulation. The results are consistent with those of the classical elastic materials when the phonon-phason coupling constant is 0. For the adhesive contact problem, the indentation force has positive correlation with the contact displacement, but the phonon-phason coupling constant impact is barely perceptible. The validity of the conclusions is verified.     

Fretting contact of two elastic solids with graded coatings under torsion

In this paper, the fretting contact problem for two elastic solids with graded coatings is investigated. We assume a conventional axisymmetric Hertzian contact takes place between two elastic solids under the action of the normal pressure. The application of the torque produces an annulus of slip. It is assumed that the surface shear traction within the contact area is limited by Coulomb’s friction law and the torsion angel was produced within the central adhesion zone as a rigid body. The linear multi-layer model is used to model the functionally graded coating with arbitrarily varying shear modulus. This model divides the coating into a series of sub-layers with the elastic modulus varying linearly in each sub-layer and continuous on the sub-interfaces. By using the transfer matrix method and Hankel integral transform technique, this problem is formulated as the solution of the Cauchy singular integral equations. The contact tractions are calculated by solving the equations numerically. The results show that the appropriate gradual variation of the shear modulus can significantly alter the contact tractions. Therefore, graded coatings may have potential applications in improving the resistance to fretting contact damage at the contact surfaces.     

粗糙面在梯度表面层上滑动接触的应力分布

对粗糙面在梯度表面层上的滑动过程进行应力分布研究,以模拟实际摩擦过程中,考虑塑性变形情况下,梯度覆层体中的应力分布规律,同时与均质体及单覆层体进行比较研究,分析了在表面载荷相同时滑动接触的应力分布。结果表明覆层体出现塑性变形后,在接触表面上的压力分布与弹性变形时有很大变化,在界面处梯度层的应力分布比单层膜更为理想,其应变梯度也较小;受相同表面载荷作用下产生塑性变形时,梯度层膜在基体产生塑性变形较小     

An embedded crack in a functionally graded orthotropic coating bonded to a homogeneous substrate under a frictional Hertzian contact

In this paper, we consider the elasto-static problem of an embedded crack in a graded orthotropic coating bonded to a homogeneous substrate subject to statically applied normal and tangential surface loading. The crack direction is parallel to the free surface. The coating is graded in the thickness direction and is orthogonal to the crack direction. This coating is modelled as a non-homogeneous medium with an orthotropic stress–strain law. The equivalent crack surface stresses are first obtained and substituted in the plane elasticity equations. Using integral transforms, the governing equations are converted into singular integral equations which are solved numerically to yield the displacement field as well as the crack-tip stress intensity factors. This study presents a complete theoretical formulation for the problem in the static case. A numerical predictive capability for solving the singular integral equations and computing the crack-tip stress intensity factors is proposed. Since the loading is compressive, a previously developed crack-closure algorithm is applied to avoid interpenetration of the crack faces. The main objective of the paper is to investigate the effects of the material orthotropy and non-homogeneity of the graded coating on the crack-tip stress intensity factors, with and without using the crack-closure algorithm, for the purpose of gaining better understanding on the behavior and design of graded coatings.     

Determination of contact temperature in cylindrical joints

The problem of determining the contact temperatures arising due to internal friction between two coated cylinders through their coatings is considered. The case of imperfect thermal contact is treated. The contact temperatures on the coating surfaces are determined in closed form.     

Analysis methods and size effects in the indentation fracture toughness assessment of very thin oxide coatings on glass

Very thin oxide coatings (<100 nm) which are used as anti-reflection and barrier layers in low emissivity architectural glass have been studied by nanoindentation methods to determine the effect of coating thickness on fracture toughness. Traditional microindentation-derived methods to determine the fracture toughness are unsuitable for assessing very thin coatings (<500 nm) and alternative energy-based models are required depending on what features are visible in indentation load–displacement curves. In cases where radial cracks are formed and grow in a discontinuous manner there are excursions in the load–displacement curve which can be the basis for analysis. In cases where picture frame cracks are observed there are no such features and an alternative approach based on assessment of irreversible work of indentation is required. This paper reviews the methods for obtaining fracture toughness data for very thin coatings and assesses the existence of size effects in the mechanical response of oxide coatings with different thickness on a glass substrate. For oxide coatings in the thickness range 100 to 400 nm no size effects in fracture toughness were observed.     

Green’s functions of a surface-stiffened transversely isotropic half-space

Green’s functions of a transversely isotropic half-space overlaid by a thin coating layer are analytically obtained. The surface coating is modeled by a Kirchhoff thin plate perfectly bonded to the half-space. With the aid of superposition technique and employing appropriate displacement potential functions, the Green’s functions are expressed in two parts; (i) a closed-form part corresponding to the transversely isotropic half-space with surface kinematic constraints, and (ii) a numerically evaluated part reflecting the interaction between the half-space and the plate in the form of semi-infinite integrals. Some limiting cases of the problem such as surface-stiffened isotropic half-space, Boussinesq and Cerruti loadings, and extremely flexible and rigid plates are also studied. For the classical Cerruti problem in transversely isotropic materials, the effects of incompressibility are highlighted. Numerical results are provided to show the effects of material anisotropy, relative stiffness factor, and load buried depth. The obtained Green’s functions play a key role in treating further mixed-boundary-value problems in surface stiffened transversely isotropic half-spaces.     

Axisymmetric contact problem of cubic quasicrystalline materials

The axisymmetric elasticity theory of cubic quasicrystal was developed in Ref. [1]. The axisymmetric elasticity problem of cubic quasicrystal is reduced to a single higher-order partial differential equation by introducing a displacement function, based on which, the exact analytic solutions for the elastic field of an axisymmetric contact problem of cubic quasicrystalline materials are obtained for universal contact stress or contact displacement. The result shows that if the contact stress has order −1/2 singularity on the edge of the contact domain, the contact displacement is a constant in the contact domain. Conversely, if the contact displacement is a constant, the contact stress must have order −1/2 singularity on the edge of the contact domain. Project supported by the National Natural Science Foundation of China (No. 19972011).     

Effect of friction on subsurface stresses in sliding line contact of multilayered elastic solids

A numerical integral scheme based on Fourier transformation approach is employed to investigate the effect of friction on subsurface stresses arising from the two-dimensional sliding contact of two multilayered elastic solids. The analysis incorporates bonded and unbonded interface boundary conditions between the coating layers. Two line contact problems are presented. The first one is the contact problem between a rigid cylinder and a two-layer half space and the second one is the indentation of a multilayered elastic half-space by a flat rigid punch. The effects of the surface coating on the contact pressure distribution and subsurface stress field are presented and discussed.     

含有多个涂层压电纤维复合材料的平面问题研究

压电纤维在未来的复合材料结构健康监测中具有重要作用．本文基于横观各向同性压电材料位移和应力连续条件以及经典的复势函数理论,讨论了同时受到平面内机械载荷和出平面电载荷作用时含有多个带涂层压电纤维的无限大线弹性基体的平面力学问题．首先将线弹性基体、涂层和压电纤维的应力场、位移场表示成复势函数,然后通过横观各向同性压电材料和线弹性材料的位移和应力连续条件确定复势函数表达式．将得到的复势函数表达式代入线弹性基体、涂层和压电纤维的的应力场、位移场公式可确定其应力场和位移场．最后,通过定量的案例讨论了涂层的材料属性对线弹性基体应力场的影响．案例分析表明涂层的材料属性对压电复合材料的应力场有重要的影响．     

Stress field of a coated arbitrary shape inclusion

This paper presents an effective method for the plane problem of a coated inclusion of arbitrary shape embedded in an isotropic matrix subjected to uniform stresses at infinity. Based on the complex variable method combined with the expansion of Faber series and Laurent series, the complex potentials in the matrix, the coating and the arbitrary shape inclusion are given in the form of series with unknown coefficients. The stress and displacement continuous conditions on the interfaces are then used to produce a set of linear equations containing all the coefficients. Through solving these linear equations, the complex potentials are finally obtained in the three phases. Additionally, numerical results are presented and graphically shown to investigate the influence of inclusion geometry and coating on the stress distribution along the interfaces for the cases of a coated elliptic, square and triangle inclusions, respectively. It is found that the coating has little effects on the interface stress for a hard inclusion, while it impacts greatly for a soft inclusion. Especially, it is also found that the stresses show the nature of intense fluctuations near the corner of the triangle inclusion, since the inclusion in this case is similar to a wedge.     

Thermoelastic contact mechanics for a flat punch sliding over a graded coating/substrate system with frictional heat generation

The problem of thermoelastic contact mechanics for the coating/substrate system with functionally graded properties is investigated, where the rigid flat punch is assumed to slide over the surface of the coating involving frictional heat generation. With the coefficient of friction being constant, the inertia effects are neglected and the solution is obtained within the framework of steady-state plane thermoelasticity. The graded material exists as a nonhomogeneous interlayer between dissimilar, homogeneous phases of the coating/substrate system or as a nonhomogeneous coating deposited on the substrate. The material nonhomogeneity is represented by spatially varying thermoelastic moduli expressed in terms of exponential functions. The Fourier integral transform method is employed and the formulation of the current thermoelastic contact problem is reduced to a Cauchy-type singular integral equation of the second kind for the unknown contact pressure. Numerical results include the distributions of the contact pressure and the in-plane component of the surface stress under the prescribed thermoelastic environment for various combinations of geometric, loading, and material parameters of the coated medium. Moreover, in order to quantify and characterize the singular behavior of contact pressure distributions at the edges of the flat punch, the stress intensity factors are defined and evaluated in terms of the solution to the governing integral equation.     

Combined photoelastic and electrical-analog method for solution of plane-stress plasticity problems

A new application of the electrical-analog method is introduced for the evaluation of the\(\varepsilon _z - principal\) strain, normal to the surface of a thin sheet loaded under conditions of plane stress in plasticity. The analogy relating the two physical phenomena of\(\varepsilon _z - strain\) distribution in a plane-stress plastic field and the potential φ of a plane electrostatic field is based on the assumption that the Cartesian components of strain parallel to the surface of the body vary along the thickness of the strip. They are expressed as a sum of a term independent ofz and a second term, which is a second degree function of thez-coordinate normal to the surface of the body. The boundary conditions of the\(\varepsilon _z - strain\) distribution may be easily determined by a photoelastic method using birefringent coatings cemented on the surface of the metallic specimens. Then, the electrical analogy can be applied for the evaluation of the\(\varepsilon _z - strain\) distribution all over the field. The graphited paper was used as conducting surface in the application of the analogy. The values of\(\varepsilon _z - strain\), together with data obtained by the birefringent coating and concerning the two other Cartesian components of strain, yield an explicit analytic solution of the elastic-plastic plane-stress problem. The method is applied to a plane-stress restricted plasticity problem of a thin slab, with two semicircular grooves in pure tension. The results were compared with those obtained by a photoelastic pointwise solution using normal and oblique incidence. The agreement between these results shows the accuracy of the method.     

Contact problems on soft and rigid coatings of an elastic half-plane

The solutions of contact problems on a soft or rigid coating of an elastic half-plane are of great practical interest. Accordingly, the present paper is divided into two parts: in the first part, we consider the problem of interaction between a rigid biquadratic die and an elastic half-plane through a thin soft coating; in the second part, we consider the problem of interaction between a rigid plane die and an elastic half-plane through a thin rigid coating. We derive integral equations for the problems under study and construct their approximate solutions by a regular asymptotic method. Earlier, the question of studying such problems was posed, for example, in [1–3]. Here we use these results to a large extent.