We used an object oriented finite element numerical method to examine residual stress build-up in a simulated crosssection of coating. The cross-section image of coating was the result of simulation produced by a 3-D stochastic model of thermal spray coatings, which model features of coating microstructure including internal pores and surface roughness. An adaptive meshing technique was used to fit a grid in a section through the simulated coating, and stresses in the coating calculated using a finite element method. The results showed that stresses are sensitive to the thickness and roughness of the coating.

The spreading and solidification of a molten droplet is governed a number of factors such as fluid inertia, viscosity, surface tension, surface wettability, heat transfer between the droplet and substrate, and surface thermal properties. Most numerical and experimental studies of droplet impact have considered a single molten droplet landing on a flat, solid surface. This paper investigates the sequential deposition of tin droplets with their centers offset using a three-dimensional model of droplet impact and solidification. In this study, the successive deposition of two tin droplets on a stainless steel substrate is simulated and the results are compared with photographs of impacting droplets. Paper includes a German-language abstract.

A three dimensional model of coating formation has been developed. Using the model we are able to simulate coating formation by deposition of large numbers of droplets. The properties of impacting particles are assumed to vary stochastically using a normal probability density function. Splat curl up is assumed to be the source of porosity formation. The model is able to predict coating porosity, thickness and roughness as a function of spray parameters.