Modelling and simulation of process-integrated powder coating by radial axial rolling of rings

In this paper, we present finite element (FE) process simulations of a new production method used to coat ring-shaped work pieces with functional layers. Similarly to the conventionally applied hot isostatic pressing (HIP), this new coating method is based on powder metallurgy. It is expected to overcome some important drawbacks by integrating the consolidation of the powdery layer material into the hot rolling of the substrate ring. This makes HIP dispensable. Nevertheless several difficulties arise through the process integration. E.g., the presence of the compactable layer requires a different handling of the rolling stage compared with classical ring rolling. FE simulations shall support the design of this new process in order to investigate critical process parameters. For this purpose, new finite element modules have to be developed. A crucial point is the adequate modelling of the layer material. In this regard, we present a rate-dependent finite strain material model that describes the consolidation of the layer material in a thermodynamically consistent way. Moreover, FE process simulations of the new production method are presented and compared with experimental results.