Residual stresses in coating-based systems, part II: Optimal designing methodologies

Abstract

In this part of the work, different cases are studied to illustrate the implementation of the analytical models that have been developed in Part I [Front. Mech. Eng. China, 2007, 2(1): 1 12]. Different topics are involved in the optimal design of coating-based systems. Some essential relations among material properties and dimensions of the coating and substrate and the residual stress variations are reflected. For the multilayered coating-based systems, some optimal design methodologies are proposed, such as the decrease in stress discontinuity at the interface between the adjacent layers, the curvature as a function of the coating thickness, the effect of the interlayer on the residual stress redistribution, and so on. For the single-layered coating-based systems, some typical approximations that are often used to predict the residual stresses in the coating-based system or bilayer structure are corrected. A simplified model for predicting the quenching stress in a coating is also developed.