Simulation of the thermal history

and induced mechanical stresses

during a plasma spray coating process


K. Fataoui1*, B. Pateyron1, M. El Ganaoui1, H. Rhanim2, A. Belafhal2

1 Université de Limoges, SPCTS UMR6638, CNRS 123, av. Albert Thomas 87060 Limoges, France

2 Université Chouaïb Doukkali, Faculté des Sciences, 24000 El Jadida, Maroc

* Corresponding author. E-mail:

Received: 15 May 2007; revised version accepted: 23 September 2007


     The aim of this investigation is to combine a thermo mechanical modeling with the growing of coated material by spraying process. A numerical model has been built to describe the thermal history of a plasma spray coating. In this model the freezing of the crushed droplet (splats) by quenching and cooling creates mechanical stresses. These stresses involved cracks in the coating and also unsticking between the coating and the substrate. The practical case of alumina coating on stainless steel substrate is considered. This model tries to forecast these phenomena to put forward possible control. The 2D axisymmetrical model is based on finite element formulation. Results are compared with 1D available result and the interest of 2D extension is underlined in the present study.


Keywords: Plasma spray; Mechanical stresses; Thermal history.

© 2015