FE modeling of stress distribution in MAO coating on TC4 substrate under thermal shock cyclic loading

A numerical study using finite element analysis (FEA) was performed to investigate the thermal, shear and radial stresses developed in MAO coating on substrate of TC4 under thermal cycle loading. The four-node quadrilateral thermal solid element PLANE55 and four-node quadrilateral structural solid element PLANE42 with axisymmetric option was used to model the temperature distribution and thermal stress field of the MAO coating on TC4 substrates. The thermal stress, radial stress and shear stress along the thickness in film/substrate system are analyzed systematically under different thermal cycle loading. It is found that the thermal stress of MAO coating exhibits a linear relationship with thickness of substrate, but it exhibit a parabolic relationship with the thickness of the coating. The radial stress and shear stress distribution of the coating-substrate combination are also calculated. It is observed that high tensile shear stress of MAO coating on TC4 substrate reduces its adhesive strength but high-compressive shear stress improves its adhesive strength.