FE modelling of surface stresses in erosion-resistant coatings under single particle impact

A finite element methodology was developed to investigate tensile stresses in the surface of multilayered coatings under single particle impact, simulating particulate erosion conditions. Eight different coating architectures were analyzed to determine reduction in tensile stresses obtained through a combination of layering patterns and material property selections. Depending on actual layer configuration and materials properties used in the calculations, differences in tensile stresses up to 3.6 times were observed. In addition, the role of a bond coat and a load-spreading layer were analyzed to assess their effectiveness in erosion-resistant coatings. Overall, the best coating architecture, from the standpoint of maximizing tensile stress reduction, was the one with a thin, low-modulus top layer and a thick, high-modulus bottom layer.