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INSTITUTE OF PHYSICS PUBLISHING MODELLING AND SIMULATION IN MATERIALS SCIENCE AND ENGINEERING

Modelling Simul. Mater. Sci. Eng. 13 (2005) 935–979 doi:10.1088/0965-0393/13/6/011

Coatings and surface modification technologies:a finite element bibliography (1995–2005)

Jaroslav Mackerle

Department of Mechanical Engineering, Linkoping Institute of Technology,SE-581 83 Linkoping, Sweden

Received 15 June 2005Published 4 August 2005Online at stacks.iop.org/MSMSE/13/935

AbstractThis paper gives a bibliographical review of the finite element methods appliedto the analysis and simulation of coatings, their mechanical and materialproperties from the theoretical and application points of view. The surfacemodification technologies in the context of coatings are also included. Theadded bibliography at the end of this paper contains 1032 references to papersand conference proceedings on the subject that were published in 1995–2005. The following topics are included: coating property simulations; surfacemodification process simulations and practical coating applications.

1. Introduction

The output of scientific papers in general is fast growing, and professionals are no longerable to be fully up-to-date with all the relevant information. The increasing specializationin various engineering fields has resulted in the proliferation of subject-oriented journals andconference proceedings directed to specialist audiences. The researchers have more channelsat their disposal for communicating the results of their research, but, on the other hand, tofind necessary information may be a time-consuming and difficult process. Another questionis whether researchers/scientists are willing to spend time looking for information instead ofdoing their own research. It has been pointed out that in engineering, informal knowledgechannels are the most frequently used means of obtaining information.

In the last almost four decades the finite element method (FEM) has become the prevalenttechnique used for analysing physical phenomena in the field of structural, solid and fluidmechanics as well as for the solution of field problems. The FEM is a useful tool because onecan use it to find out facts or study the process in a way that no other tool can accomplish.

Available surface engineering systems (single, duplex or multi-layered) combatcomponent degradations of various types and meet requirements of new developed systemsworking under severe conditions, stressing and environmental. The finite element methodassists in a better understanding of their mechanical and chemical properties, manufacturingprocesses and service behaviour.

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This bibliography provides a list of references on finite element modelling and simulationsof coatings and surface modification technologies. General solution techniques as well asproblem-specific applications are included. The emphasis is to present papers first publishedin journals. These type of papers are relatively easy to obtain.

The entries in this bibliography have been retrieved from the author’s database and aregrouped into the following sections.

• Coating property simulations

◦ Material and mechanical properties◦ Hardness and indentation◦ Residual stresses◦ Fracture mechanics and fatigue

• Surface modification process simulations

◦ Surface modification process simulation in general◦ Welded coatings and cladding◦ Sprayed coatings◦ Physical and chemical vapour deposition◦ Electrochemical and chemical deposition◦ Other techniques

• Practical coating applications

◦ Electronics and electrical engineering◦ Biomechanics◦ Material processing and machining◦ Turbines◦ Other applications

The bibliography is organized in two main parts. In the first one each topic is handledand current trends in modelling techniques are mentioned, usually as the keywords. Thesecond part, the appendix, contains a list of papers published in open literature in theperiod 1995–2005 (first three months of 2005) on subjects listed above. References havebeen retrieved from the author’s database, MAKEBASE [1]. Also the COMPENDEXand INSPEC databases have been checked. Readers interested in the finite elementliterature in general are referred to the author’s Internet Finite Element Books Bibliography(http://www.solid.ikp.liu.se/fe/index.html) where approximately 500 book titles are listed andcompleted with bibliographical data, abstracts and their contents.

This bibliography contains the following parts: coating property simulations, where theemphasis is on material and mechanical properties of coatings including analyses of contactand fracture mechanics problems, surface modification process simulations, where FEMs areapplied to simulate thick and thin coating processes, and finally practical coating applicationsin various fields of engineering.

2. Coating property simulations

The surface engineering system includes the surface, subsurface, interface and substrate.Together these items affect, under operating conditions, the performance of the whole system.To simulate the specific system numerically is quite a difficult problem because the mechanicaland chemical properties are complex functions of environment, surface roughness, structureand structural gradient, preferred orientation, etc. There are many experimental techniquesused to determine the coating properties. Results of these are applied in finite element

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simulations to help in the further development of new systems or to determine the behaviourof the system under changed operating conditions.

To name some experimental techniques: the nanoindentation is used to measuremechanical properties of thin coatings; the scratch techniques determine the adhesion strengthand load bearing capacity; the interfacial fatigue testing measures the cyclic bonding strengthof the coating under dynamic loads, etc.

The reason for coating the original material is to improve wear and/or corrosion, electricalproperties or for the reclamation of lost material. Wear of materials occurs during the interactionof two surfaces or during the interaction of an exposed surface to chemicals, heat, fluids orabrasive particles. The surface system covers a wide range of coating thicknesses from severalcentimetres to a few microns depending on the surface modification techniques used. Weare talking about thick or thin coatings with the following differences: in thick coatings theproperties of original material/substrate are irrelevant, the coating is self-supporting. In thecase of thin coating the properties of the substrate are important, dictating conditions such asload or environment.

High-temperature alloys/superalloys have originally been developed for gas turbines. Athigh temperatures the surface oxidation can lead to oxide layer formation where hardness andstability play an important role in thermal wear. Wear is strongly dependent on the shear stressor the shear yield stress of specific material. The performance of high-temperature structuralmaterials can be enhanced by coating, for example, by applying a thermal spray coating ofalumina, MCrAlY or with thermal barrier coatings. A commonly used thermal barrier coatingmaterial is stabilized zirconia (with Y, Mg, Ca, Ce as the stabilizers). Finite element analysesof these coatings are also included in this section.

Using the impact tests and finite element simulation algorithms, the time-dependent stress–strain laws for thermal barrier coatings can be determined. The creep phenomenon occurs if thecoating is periodically loaded over a critical stress value through impact. The operational max-imum equivalent stress has to be lower than the corresponding critical stress value determined.

Functionally graded materials are also used in high-temperature applications. Mostof them are particle-reinforced composites that distribute particles in the matrix, and theircompositions depend on position. The functionally graded materials are sandwiched betweensubstrate- and/or coating-layers. The layers can be divided into the following regions: metal-rich region, ceramic-rich region and the metal/ceramic perfect mixture region. The effects ofvarious parameters of these layers on the behaviour of the whole structure can be studied byfinite element methods.

This section contains subsections as follows: material and mechanical properties; hardnessand indentation; residual stresses and fracture mechanics and fatigue.

Material and mechanical properties

Topics included: finite element macromechanic, mesomechanic and micromechanic analysisof material and mechanical properties of thick and thin coatings; nanomechanical response;linear and nonlinear deformation and stress analysis; analysis of thermal stresses; yieldbehaviour; cohesion, adhesion and creep properties; tribological characterization; oxidationbehaviour; corrosion behaviour; damping performance; contact stresses; coating undersliding and oscillating sliding contact; rolling contact problems; wear mechanism; microwearmechanism of coating; thermal shock properties; thermal expansion; phase transformation;displacement and cyclic instabilities in thermal barrier systems; buckling instability; vibro-acoustic behaviour; effect of coating geometry on contact stresses; effects of porosity; strainanalysis and measurement and coating testing.

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Type of coating: layered and multilayered coatings; thermal barrier coatings; functionallygraded materials; discrete and blended coated solids; porous squeeze films; compositecoatings; polymer coatings; rubber coatings; coated fibre polymer composites; metal coatedfibres; coated optical fibres; ceramic coatings; organic coatings; galvanized coatings; hardcarbon coatings; carbon–carbon composites; aluminium and copper films; silver coatings;diamond coatings; zirconia, silicon oxide, aluminium oxide, nickel oxide, zinc coatings;elastomer coated fabrics and titanium based composites.

Owing to limited space in this paper, finite element analyses of piezoelectric/piezoceramiccoatings are not included. Readers interested in this subject are referred to [2, 3].

Hardness and indentation

The mechanical properties of thin films deposited on structural alloys play a critical role indetermining their durability. These films enhance the abrasion or/and corrosion resistanceof the component. By means of ultra-microhardness or nanoindentation measurementssome relevant properties of films can be determined. The nanoindentation measurementscontinuously register the course of the applied force versus the occurring penetration depth.The finite element modelling applied gives quantitative strain information used to estimatethe fracture toughness of the film, the friction coefficient on the surface and the constitutivebehaviour of the substrate. Wear on films can be studied by simulating tangential and/ornormal forces on an indenter that penetrates into the coating. Ultra thin films are used formicromechanical applications, and their mechanical properties are of interest.

Readers interested in indentation measurements and finite element analysis of indentationproblems in general are referred to [4, 5].

Topics of this subsection are: finite element simulations of microindentation andnanoindentation process; depth-sensing indentation; indentation creep testing; indentationunloading; stress–strain curve determination; determination of mechanical properties; internalstress; determination of elastoplastic or viscoplastic properties; hardness determination;measurement of residual stresses; micromechanical properties; anisotropic mechanicalproperties; indentation-induced cracking; indentation delamination; interface toughnessmeasurement; adhesion toughness; indentation and phase transformation; effect of substrateproperties; intrinsic film properties; yield strength measurement; size effect on indentation;interface influence on hardness measurement; indentation impression—conical, spherical,cylindrical and wedge and Berkovich nanoindentation.

Type of coating: thick and thin; brittle and ductile; soft films on hard substrate; hardcoating on soft substrate; thin hard coatings; thin metallic films; ceramic coatings; polymercoatings; thermal barrier coatings; sol–gel derived films; PVD films; CVD diamond coatings;metal–ceramic thin films; nanocomposite coatings; amorphous–tetrahedral carbon films; TiNsubmicron films; submicron silica films; silicon nitride films; gold films; nickel–aluminiumcoatings; nanocrystalline silver and nickel composites; aluminium coatings on borosilicateglass; porcelain–metal bilayers and multilayered hard carbon films.

Residual stresses

The mechanical properties in coatings such as hardness, adhesion, fracture strain, etc areinfluenced by the presence of residual stresses. Residual stress can be the cause of poor substrateadhesion and can also contribute to the failure of the coating. The growth of these stressesis influenced by the expansion mismatch between the coating and the substrate exposed to atemperature gradient and growth stresses from phase transformations. Finite element studies


can help to understand the effect of coupling between the temperature and stress/strain fieldsand the phase transformation, and the evolution of residual stress within coatings can be studied.

The finite element techniques can also be used to study the effect of the coating on thermalresidual stresses generated in composites at the fibre/matrix interface due to differences in thethermal expansion coefficient between the various materials of the system. These residualstresses influence fracture mechanics properties of the specific composite.

Subjects under consideration: finite element modelling of residual stresses in varioussurface modification techniques; micromechanical and macromechanical approaches; transientresidual stresses; residual stress evolution; modelling oxidation induced stresses; effect ofresidual stresses on strength; effect of deposition temperature and thermal cycling; effect ofporosity; effect of surface roughness; effect of substrate thermal expansion coefficient; effectof residual stress on thickness and interlayer of coating and determination/measurements ofresidual stresses.

Residual stresses in: hard coatings; metallic and dielectric coatings; ceramic coatings;composite films; titanium nitride coatings; diamond coatings; zirconia coatings; PVD films;borided layers on steel; functionally graded coatings and thermal barrier coatings.

Fracture mechanics and fatigue

Most published papers listed in the appendix deal with finite element analysis of fracturemechanics and fatigue problems.

Coating systems are usually stressed under cyclic loadings with the result that the coatingmaterial sometime debonds from the substrate due to tangential and normal forces acting onthe surface. Between the coating and substrate, cracks start to form and propagate. Alsonew cracks are formed faster than in a monolithic material. The behaviour of interface cracksbetween coating/substrate has been studied by finite element techniques.

The adhesion strength between coating and substrate is an important factor to evaluate thereliability as well as performance of the specific coating system. Many experimental methodsare available for its evaluation (i.e. scratching and indentation tests) but also finite elementstudies are known and listed in the appendix.

Thin hard coatings (i.e. diamond-like carbon, titanium nitride/carbonitride) improvethe tribological properties of sliding surfaces of machine components by reducing frictioncoefficients and wear rates, often without changing the substrate material or needing thelubricants. The main problem in their applications is the fracture of the coating, delaminationand spalling at the interface of the coating and the substrate. The finite element method canbe used to study the contact stresses due to normal and tangential forces and to investigatethe stresses for various values of parameters such as the coating thickness, friction coefficient,Young’s modulus ratio for coating and substrate, etc. It is important to identify the origin ofthese stresses and to minimize them.

The lifetime of thermal barrier coatings is limited by delamination that can continue to thespalling fracture. The crack propagation perpendicular and parallel to the heated surface is thecrucial factor. The finite element technique makes it possible to study the way delaminationand spalling fracture could be limited/suppressed by means of material properties gradientswithout reducing the barrier effect.

Oxidation of the ceramic top coating of a thermal barrier coating is an important factor thataffects the durability during the operation. This oxidation facilitates coating failures but themechanism is still poorly understood. Other influencing factors are bond coating coefficientof thermal expansion, creep behaviour of layers, bond coat roughness, etc. Some papers arelisted in the appendix where the FEM is applied to characterize the effects of the oxidation

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process on the stresses within the whole system and to examine the interaction of oxidationwith the other parameters that affect the lifetime of the thermal barrier system.

Metal and ceramic are used to form functionally graded materials, where ceramic supportsthermal barrier effects and provides protection for the metal from oxidation and corrosion, andmetal is the strengthened material part. The mismatch of material properties of this compositesystem may cause the crack that originates from the coating surface and expands perpendicularto the interface following penetration into the substrate. The knowledge of the failure and itsmechanism is very important to determine the safety of the designed structure. Relevant finiteelement studies have been published and are listed in this paper.

Surface coatings increase the surface hardness of the component and provide a betterwear resistance. Another important factor for the service life is the fatigue behaviour ofthe substrate that may be affected by changes in the residual stress and microhardness. Finiteelement models and experimental tests have been developed with the aim of giving the designera tool for predicting fatigue behaviour and lifetime of respective thin-coated component.

Topics of this subsection: two- and three-dimensional linear and nonlinear, staticand dynamic finite element studies of fracture mechanics problems; macromechanical,mesomechanical and micromechanical approaches; failure mechanics of coatings; crackingand multiple cracking; crack initiation; crack formation and growth; crack propagation;crack face friction effect; creep cracks; crack bridging; cracking patterns; single and doubledeflection of cracks; short crack behaviour; edge cracking; microcracks; crack generation andfracture toughness; bond strength; interfacial shear strength; mechanical strength and wearbehaviour; adhesion toughness; delamination strength; delamination cracking; residual stress-driven delamination; fracturing during cooling; energy release rate for decohesion; thermalfracture of interfaces; buckling driven delamination; contact induced cracking; mechanics ofdelamination; mechanics of damage initiation and growth; contact damage; microdamage;thermal cycle damage; dynamic damage; multidamage evaluation; fracture mechanics underindentation; coating abrasion; fracture intensity factor; fracture mode transition; biaxialfragmentation; debonding of graded coatings; fatigue behaviour of coating; fatigue crackgrowth; thermal fatigue; fretting fatigue; lifetime estimation and detection of defects.

Types of coatings under consideration: thin and thick coatings; thin hard coatings; brittlecoatings; multilayered coatings; organic coatings; porous coatings; carbon steel coatings;stainless steel coatings; ceramic coatings; cermets; ceramic–matrix composites; polymermatrix composites; coated fibre composites; silicone carbide coatings; TiN coatings; WC films;WC-Co coatings; diamond coatings; ceramic functional coatings; porous alumina; glass thinfilms; galvalume coatings; PVD and CVD coatings; porcelain/metal and porcelain/polymerbilayers; fluoric resin coatings; nanocomposite coatings; functionally graded materials andthermal barrier coatings.

3. Surface modification process simulations

Finite element process simulations provide important information and data concerningstructural changes as a result of a specific process and help to control the own process forspecified implementations. These simulations can also give information about the suitabilityof the process for a specific design of the component. To simulate the process correctly theunderstanding of various physical, chemical and metallurgical reactions is supposed.

In this section the finite element method has been applied to simulate the following coatingtechniques: surface modification process simulation in general; welded coatings and cladding;sprayed coatings; physical and chemical vapour deposition; electrochemical and chemicaldeposition and other techniques.


In welding surfacing a material (metal, alloy, cermet) is fused to the substrate or discreteareas of the substrate using filled electrodes or powders. In cladding the coating material ispre-formed and then bonded to the substrate. The coatings represent the upper limit of coatingthicknesses.

In spraying techniques powders or wires (metal, ceramic, cermet) are heated into a semi-molten state and deposited at high speeds on the substrate surface. Obtained thicknesses arein the range 0.05–1.0 mm. The most frequently used spraying techniques are: flame spraying,electric arc spraying, plasma spraying and high velocity spraying.

The vapour deposition techniques can roughly be divided into physical vapour depositionand chemical vapour deposition. With use of these techniques the coating thickness is in therange of a few microns. The process consists of the evaporation and subsequent deposition ofa coating material from its vapour phase onto the substrate. When the carried medium of thecoating material is high intensity electron or ion beam, or electrical heating, the process is calledphysical vapour deposition (PVD). In PVD the evaporative source can also be replaced by asputtering action; i.e. vaporizing the target material by ion bombardment from the plasma glowdischarge. The chemical vapour deposition (CVD) covers a range of compound and metalliccoatings produced by high-temperature gas-phase reactions. Ceramic coatings applied incutting/forming operations, chromizing, aluminizing or siliconizing are frequently used CVDtechniques.

The electrochemical (electroplating) deposition is basically the process of depositing ametal in an electrolytic cell. Electroplated coatings of chromium, nickel, cobalt, copper, zincand cadmium are commonly used for wear and corrosion protection or for specialist electricalproperties. These metals can readily be deposited from aqueous solutions. In the chemicaldeposition process the component is immersed into a reactive solution from which the coatingmaterial deposits onto the surface. Some specific processes are phosphating, electroless nickelcoatings, chromium oxide-based coatings, etc.

In the last subsection the processes such as for multicomponent coatings or sol–gel areincluded. In the multicomponent coatings multiple layers of different coatings can be formedon the same surface by applying more than one deposition process. Sol–gel process consistsof the dissolution of a sol material and the deposition of a gel/colloidal compound on thesubstrate. The dried surface has a high level of fine porosity.

For a more detailed description of surface modification techniques see, for example [6,7].A comprehensive treatment of material and mechanical properties of coatings is also givenhere. Surfaces can also be modified without either changing their composition or addinga coating material. In this case the metallurgical condition is altered through a thermal ormechanical working process. For this type of process the references are not included in thisbibliography. Readers interested in finite element analysis and simulation of quenching andother heat treatment processes are referred to [8].

Papers dealing with finite element analyses and simulations of the above described surfacemodification processes are listed in the following subsections.

Surface modification process simulation in general

Topics: surface engineering design; thick and thin film material design; multiscaleatomistic-continuum modelling; modelling of coating–substrate systems; modelling of thinlayers; modelling of coating flows; modelling of functionally gradient thermal barriercoatings; diffusion through optical fibre coating; three-scale modelling of heterogeneousmedia; optimization of wear-resistant coatings; software descriptions; distributed parallelprocessing.

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Welded coatings and cladding

Topics: finite element simulations of cladding process; laser cladding; coaxial laser cladding;laser cladding by powder injection; electroslag cladding; explosive compaction/cladding;welded overlay cladding; spiral weld cladding; segmented cladding; hydrostatic extrusionof cladded tubes; rolling deformation of clad materials; continuous casting of cladded slabs;cold-formed steel cladding; cladding process in bimetallic rod extrusion; thermomechanicalmodelling; fracture mechanics in cladding; cladding effects on fracture toughness; effectof cladding on stress intensity factor; singular cladding stresses; cleavage fracture of claddedspecimens; contact fatigue resistance; void formation in cladding; residual stresses in cladding;constraint effects of clad; electrical and thermal effects; load carrying capacity; cladding underblast loading; thermal shock on cladded plates; transfer of impulsive loading; tailoring ofovercladding; irradiated cladding.

Cladding materials: steel cladding; stainless steel cladding; high strength steel cladding;clad sheet metal; plasterboard-cladding; hydrided cladding; Inconel-clad tungsten; zircaloycladding; Al/Cu clad composites; copper-clad aluminium; copper clad laminates; fibres;metal-clad optical fibres; concrete cladding; layered cladding.

Sprayed coatings

Topics: finite element analysis of spraying processes; micromechanical and macromechanicalapproaches; plasma sprayed coatings; thick plasma sprayed coatings; plasma thermalspraying; air plasma spraying; low pressure plasma spraying; cold gas spraying; twin wirearc spraying; thermal sprayed coatings by laser irradiation; thermal stresses; phase changemodelling; microstructural characterization; interlayer effect on residual stresses; residualstresses; creep behaviour and relaxation; oxidation-induced degradation; porosity effects;effect of coating thickness; effect of substrate surface roughness.

Type of coating: aluminium; zirconia; lead coatings; ceramic coatings; layer composites;functionally graded coatings; thermal barrier coatings; MgO–ZrO2 coating; NiCoCrAlYcoating; Cu-8Cr-4Nb coating; 80Ni20Cr coating; NiCrAlY coating; Y/20/3-PSZ coating.

Physical and chemical vapour deposition

Topics: finite element simulation of PVD and CVD processes; micromechanical andmacromechanical approaches; electron beam PVD; laser CVD; metal organic CVD; ionassisted deposition; ion beam assisted filtered cathodic vacuum arc deposition; CVD fibrecoating; laser evaporative heating; solvent evaporation; evaporative material removal; selectivearea laser deposition; low energy deposition; CVD reactors; sputtering; thermal stresses;residual stresses; evolution of interfaces; intrinsic stress variations; morphology problems.

Type of coating: carbon on graphite; Al(O) alloys; silicon carbide; carbon nitride thin films;tin films onto a tungsten carbide surface; glass substrates with tin oxide; silica on polycarbonateand steel; diamond films; polycrystalline diamond; ceramic coatings; boron doping silicon;fibres; metal/ceramic multilayered composites; thermal barrier coatings; gradient thermalbarrier coatings; titanium evaporation.

Electrochemical and chemical deposition

Topics: finite element simulations of electrochemical and chemical deposition processes;electroless coating process; electrodeposition; fused deposition; phosphating; thermochemical


treatment combined with coating; metal electrochemistry and coating characterization; flowmodelling.

Type of coating: zinc phosphate; nickel on silicon; nickel thin films; copper thin films;fibres.

Other techniques

Topics: direct gravure coating; coating process between two rolls; tribo-charge powder coating;die coating; co-injection moulding; laser sintering of polymer-coated metal powder; deepdrawing of coated steels; stretch forming of coated steels; in-mould coating; coatable spliceprocess; blade coating; wire coating; cable coating; forward roll coating; sol–gel process; coldforging TiN coated tool steels; consolidation of metal matrix coated fibre composites; wallironing process; slot coating; spin coating; web roll coating process; reverse roller coating;coatings with laser melt injection of particles; press forming; simulation of coating flows;drying in coatings; decoating process.

4. Practical coating applications

This section deals with finite element analysis of specific industrial structures or componentsas well as coating applications in other fields of engineering. References in the appendixare listed under the following headings: electronics and electrical engineering; biomechanics;material processing and machining; turbines; and other applications.

Electronics and electrical engineering

Coatings applied to: nanoelectronic devices; chip-on-board packages; VLSI systems; FBGsensors; multichip modules; capacitive microintegrated gas sensors; casings of fragileelectronic equipment; composite bushings; silicon-on-insulator waveguides; surface-mountedPM SM; radar cross-section of coated cylinders; stainless-to-Kovar packages; silane coatedmicrocantilevers; wafers with film coating; electrodes; flip-chip packages; membranes; soldercolumns; protective thin layers on devices; thin film transistors; temperature sensors; micro-drop coated gas sensors; metal-coated Si springs; metal-coated fibre Bragg gratings.

Biomechanics

Most papers where the finite element method has been applied to biomechanical problems dealwith coatings on metal implants that are widely used in orthopaedic and dental applications.The quantitative understanding of coating deformation enables to elucidate the mechanicalstability of these implants in clinical applications. Consequently, the coating process can beimproved to achieve better in vivo life span for coated implants. Another problem is the coatingfailure as a result of shear loading. Also here the finite element method helps to study shearstrength and fatigue of coating/implant systems.

Coatings applied to: total hip femoral stems; porous coated implants; intramedullaryimplants; cancellous bone-porous coated metal interface; coated hip endoprosthesis; fullycoated beaded implants; coated dental/oral implants; effect of porous coating on stressshielding; effect of coating placement; bioglass-coated alumina interbody grafts; adhesionof bioactive glass coatings; drug release through deformed coating film.

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Material processing and machining

Coatings applied to: dies used in material processing; coatings for glass-moulding dies;coated carbide cutting tools; PM coated tools; coated tools for dry machining; coated inserts;multilayered coated tools; multicoated forming and cutting tools; coating on HSS substratein milling; milling performance of cemented carbides inserts; high speed machine toolspindles; coated hardmetal tools for turning; cutting performance of coated tools at elevatedtemperatures; effects of geometry and coating; improving tool performance; polymer films inmanufacturing; wear resistant two-phase coatings.

Turbines

Thermal barrier coating deposited onto turbine alloys has two major benefits: the cooling airrequirements can be reduced, and the hot gas temperature can be raised. Roughly speaking itmeans that turbines can be operated at higher temperatures while maintaining an acceptabletemperature range within the substrate.

Main topics include: coatings for gas turbine blades; blade coating with free jet applicator;oxidation-limited component lifetime in turbines; ceramic matrix composite vane sub-element;effect of coating thickness; heat transfer analysis; fatigue mechanisms.

Other applications

The following topics are included: coating applications in pressure vessels and piping; coatingapplications in automotive industry; coating applications in reactor technology; aerospaceapplications; coated fins; pipelines with thick insulation coating; gas pipelines with imperfectcoating; tubes with composite coating; pipes with cladding; concrete cladding panels; pipelineswith concrete coating; imperfect insulator coatings; automotive paint systems; coated pistons;ball bearing coatings; pellet-clad thermomechanical interaction; fuel cladding; ship ballasttanks; risers with neoprene coating; optical membrane mirrors.

Acknowledgment

The bibliography presented in the appendix is by no means complete but it gives acomprehensive representation of different finite element applications on the subjects. Theauthor wishes to apologize for the unintentional exclusions of missing references and wouldappreciate receiving comments and pointers to other relevant literature for a future update.

Appendix. A bibliography (1995–2005)

This bibliography provides a list of literature references on finite element analyses andsimulations of coatings and surface modification technologies. The listing presented containspapers published in scientific journals, conference proceedings, and theses/dissertationsretrospectively to 1995. References have been retrieved from the author’s database,MAKEBASE. Entries are grouped into the same sections described in the first part of thispaper and sorted alphabetically according to the first author’s name. In some cases, if aspecific paper is relevant to several subject categories, the same reference can be listed underthe respective section headings, but the interested reader is expected to consider also areasclose to his/her central area of research interest.


Coating property simulations

Material and mechanical properties

Ager J et al 1996 Growth and mechanical and tribological characterization of multi-layer hard carbon films Mater.Res. Soc. Symp. Proc. 438 581–5

Akisanya A R et al 2001 The deformation and densification of an array of metal-coated fibres Acta Mater. 49 221–35Akisanya A R et al 2001 The yield behaviour of an array of metal-coated fibres Eur. J. Mech. A—Solids 20 77–90Anderson I A and Collins I F 1995 Plane strain stress distributions in discrete and blended coated solids under normal

and sliding contact Wear 185 23–33Asif S A et al 1995 Nanomechanical response of materials and thin film systems: finite element simulation Stress

Mech. Prop. Mater. V 356 (MRS) 677–86Baker M and Rosler J 2003 How creep properties influence the stress state of thermal barrier coatings Mater. Sci.

Forum 426–432 2527–32Balke H et al 1995 Zum mechanischen Stabilitatsverhalten von Zwillingskorngrenzen in dunnen Schichten ZAMM

75 S141–2Bennani H H and Takadoum J 1999 Finite element model of elastic stresses in thin coatings submitted to applied

forces Surf. Coat. Technol. 111 80–5Beygelzimer Y E and Spuskanyuk A V 1999 The thick yield surface: idea and approach for investigating its structure

Phil. Mag. A 79 2437–59Boggs S et al 2002 Effect of silver coating thickness on high current contact stability Int. Symp. Electr. Insul. (Boston)

(Piscataway, NJ: IEEE) pp 444–8Bouzakis K D et al 2001 Characterization of cohesion, adhesion and creep properties of dynamically loaded coatings

through the impact tester Z. Metallk. 92 1180–5Bouzakis K D et al 2004 The inclined impact test, an efficient method to characterize coatings’ cohesion and adhesion

properties Thin Solid Films 469–470 254–62Brand J et al 2002 Diamond-like carbon coatings—a new design element for tribological applications Indust. Lubric.

Tribol. 54 291–5Bruck H A and Surendranath H 2001 Minimization of stress at metal–ceramic interfaces using functionally graded

materials ASME Int. Mech. Eng. Congr. Expo. MD 95 (ASME) pp 9–15Buravalla V et al 2001 Enhancement and evaluation of damping performance in layered CLD type coatings Proc.

SPIE 4331 198–208Cederholm A 2003 Homogeneous models of anechoic rubber coatings PhD Thesis KTH, Stockholm, SwedenCederholm A N P 2003 Acoustic properties of Alberich rubber coatings subjected to an applied ambient pressure

10th Int. Congr. Sound Vib. (Stockholm) pp 2515–22Celik E et al 2003 Thermal analysis of high temperature ZrO2 insulation ceramic coatings on Ag tapes used as sheath

of Bi-2212 superconducting materials using FEM Mater. Des. 24 543–6Challapalli S et al 2000 Finite element modeling of thermal stresses in MoSi2 and MoSi2 + SiC composite coatings:

a preliminary study Surf. Eng. Mater. Sci. Symp. vol 1, pp 3–12Chen M W et al 2003 Characterization and modeling of a martensitic transformation in a platinum modified diffusion

aluminide bond coat for thermal barrier coatings Acta Mater. 51 4279–94Chen M W et al 2003 Influence of martensitic transformation on the durability of TBC systems ASME Int. Mech. Eng.

Congr. AD 68 (ASME) pp 489–95Cherkaoui M et al 1996 Thermoelastic behavior of composites with coated reinforcements: a micromechanical

approach and applications Comput. Mater. Sci. 5 45–52Christofides C et al 2002 Wear of a thin surface coating: modelling and experimental investigations Comput. Mater.

Sci. 25 61–72Cocchini F 1995 Lateral rigidity of double-coated optical fibers J. Lightwave Technol. 13 1706–10Darzens S and Karlsson A M 2004 On the microstructural development in platinum-modified nickel-aluminide coats

Surf. Coat. Technol. 177–178 108–12Deflorian F et al 1999 Degradation of protective organic coatings after cupping test Corrosion 55 1003–11Diao D 1996 Local yield map of hard coating with an interlayer under sliding contact Thin Solid Films 290–291 221–5Diao D F 1999 Finite element analysis of local yield map and critical maximum contact pressure for yielding in hard

coating with an interlayer under sliding Tribol. Int. 32 25–32Diao D F and Ito K 1999 Local yield map and elastic–plastic deformation map of hard coating with lubricative particles

under sliding Surf. Coat. Technol. 115 193–200Diao D F et al 1996 Effect of interlayer on maximum contact stresses of hard coating under sliding contact Surf. Coat.

Technol. 86–87 480–5

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Du H L et al 2003 Oxidation and sulfidation behavior of AlTiN coated Ti-46.7 Al-1.9W–0.5Si intermetallic with CrNand NbN barriers at 850˚C Oxid. Met. 60 29–46

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sheet metal Mech. Mater. 32 423–43Van der Aa M 1999 Wall ironing of polymer coated sheet metal PhD Thesis Eindhoven University of TechnologyVan der Aa M A H et al 1997 Numerical analysis of the wall-ironing process of coated sheet metal 5th Int. Conf.

Comput. Plast. ed D R J Owen (CIMNE) pp 1439–44Van der Aa M A H et al 2001 Modelling of the wall ironing process of polymer coated sheet metal Mech. Mater. 33

555–72Verleene A et al 2000 Determination of a hardening behaviour law for a cold forging TiN-coated tool steel Surf. Coat.

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28 233–42Wang Z et al 2003 FEM analysis of contact mechanism in press-forming of lubricant precoated steel sheet J. Mater.

Process. Technol. 140 514–9Wapperom P and Hassager O 1999 Numerical simulation of wire-coating: the influence of temperature boundary

conditions Polymer Eng. Sci. 39 2007–18Woolard D E and Ramani K 1995 Electric field modeling for electrostatic powder coating of a continuous fiber bundle

J. Electrostat. 35 373–87Xie X and Pasquali M 2004 Computing 3-D free surface viscoelastic flows Computational and Experimental Methods,

Moving Boundaries VII Vol 10 (Southampton: WIT Press) pp 225–34Yalamanchili P and Baltazar V 1998 Mold compound filler induced metal crush in plastic encapsulated devices with

die overcoat Proc. SPIE 3582 73–8Yang K et al 1997 Significance of coating stress on substrate bow in large area processing of MCM 21st IEEE/CPMT

Int. Electron. Manuf. Symp. (Austin) pp 192–5Yoshida K et al 2001 Influence of coating of PM on eddy currents in PM of surface-mounted PM SM Trans. Inst.

Electr. Eng. Japan D 121 139–40Zevallos G A et al 2004 Forward roll coating flows of viscoelastic liquids Moving Boundaries VII (Southampton:

WIT Press) pp 235–44Zhong D et al 2001 Finite element analysis of a coating architecture for glass-molding dies Surf. Coat. Technol.

146–147 312–7Zhong D et al 2003 Development of surface engineered coatings for dies used in material processing TMS Annual

Meeting (San Diego) pp 183–94Zouari B and Touratier M 2002 Simulation of organic coating removal by particle impact Wear 253 488–97

Practical coating applications

Electronics and electrical engineering

Al Salameh M S 1998 Radar cross-section of coated cylinders with apertures by vector finite elements Int. J. Electron.85 651–60

Cheng W H et al 1997 Effects of Au coating on thermal stresses in stainless-to-Kovar packages Opt. Quant. Electr.29 939–51

De Boer M P et al 2000 Adhesion hysteresis of silane coated microcantilevers Acta Mater. 48 4531–41Ding H et al 2001 Warpage analysis of wafers with film coating ASME Int. Mech. Eng. Congr. Expo. EEP 1 (ASME)

pp 1–7

974 J Mackerle

Feng J Q and Hays D A 1996 Electric field detachment of a uniformly charged dielectric sphere on a dielectric coatedelectrode 1996 IEEE Ind. Appl. 31st IAS Annual Meeting (San Diego) pp 1883–90

Feng J Q and Hays D A 1998 Finite element analysis of the electrostatic force on a uniformly charged dielectric sphereresting on a dielectric-coated electrode IEEE Trans. Indust. Appl. 34 84–91

Feng J Q et al 1997 Electric field detachment of a nonuniformly charged dielectric sphere on a dielectric coatedelectrode 8th Int. Conf. Electrostat. (Poitiers) pp 289–94

Freund L B and Johnson H T 2001 Influence of strain on functional characteristics of nanoelectronic devices J. Mech.Phys. Solids 49 1925–35

Gu Y 2003 Material Characterization of thin coatings and failure analyses of flip-chip packages PhD Thesis StateUniversity of New York, Stony Brook

Hansen M S et al 2001 A mechanical impact of coatings on membranes Technical Digest MEMS 2001 pp 361–4Hong B Z and Ray S K 2000 Ceramic column grid array technology with coated solder columns 50th Electron.

Compon. Tech. Conf. (Las Vegas) pp 1347–53Huang W et al 2004 Effect of organic/inorganic coating on moisture diffusion in a chip-on-board package with globtop

J. Electron. Mater. 33 101–5Igic P M and Mawby P A 2000 An investigation of the impact of a Ti barrier metal on the thermal stress field in

passivated aluminium lines and vias in VLSI systems using FEM Int. J. Electron. 87 1289–99Jeong J H et al 2002 Mechanical analysis for crack-free release of chemical-vapor-deposited diamond wafers Diamond

Relat. Mater. 11 1597–605Langari A et al 2002 On the effect of using protective thin layers on device reliability Proc. SPIE 4828 237–42Mitchell D et al 2001 Methodology for studying the impact of intrinsic stress on the reliability of the electroless Ni

UBM structure IEEE Trans. Compon. Pack. Manuf. Tech. 24 667–72Muralt P et al 2001 Study of PZT coated membrane structures for micromachined ultrasonic transducers IEEE

Ultrason. Symp. pp 907–11Nagao M et al 2004 Fabrication of polycrystalline silicon field emitter arrays with hafnium carbide coating for

thin-film-transistor controlled field emission display Japan. J. Appl. Phys. 43 3919–22Paul J et al 2004 Improvement of thermal sensitivity of FBG sensors by combined cladding etching and polymer

coating Proc. SPIE 5272 49–55Paul J et al 2004 Bragg grating temperature sensors: modeling the effect of adhesion of polymeric coatings Sensor

Rev. 24 364–9Paul J et al 2004 Simulation of the effect of adhesion and cross sectional non-uniformity of coatings on the thermal

tuning of fiber Bragg gratings Proc. SPIE 5465 33–40Puigcorbe J et al 2002 Thermo-mechanical analysis of micro-drop coated gas sensors Sensor Actuators A—Phys.

97–98 379–85Rastani M 1997 Failure mechanism of metallization layer of a multichip module substrate ASME Int. Mech. Eng.

Congr. Expo. MD 80 (ASME) pp 469–75Singh J P et al 2004 Metal-coated Si springs: nanoelectromechanical actuators Appl. Phys. Lett. 84 3657–9Steiner F P et al 1995 Polymer coated capacitive microintegrated gas sensor Int. Conf. Solid-State Sensor Actuators

IX (Stockholm) pp 814–17Wang Y et al 2002 A study of polymeric protective coatings on casings of fragile electronic equipment Proc. SPIE

4828 123–9Wei H J et al 2005 A study of electrical stress grading of composite bushings by means of resistive silicone rubber

coating J. Electrostat. 63 273–83Woolard D E and Ramani K 1995 Electric field modeling for electrostatic powder coating of a continuous fiber bundle

J. Electrostat. 35 373–87Wu X T et al 2000 Extending the travel range of electrostatic micro-mirrors using insulator coated electrodes

IEEE/LEOS Int. Conf. Optical MEMS pp 151–2Xu B et al 2004 Thermal analysis of packaging device with metal-coated fiber Bragg grating Proc. SPIE 5349

112–6Yalamanchili P and Baltazar V 1998 Mold compound filler induced metal crush in plastic encapsulated devices with

die overcoat Proc. SPIE 3582 73–8Yang K et al 1997 Significance of coating stress on substrate bow in large area processing of MCM 21st IEEE/CPMT

Int. Electron. Manuf. Symp. (Austin) pp 192–5Yang K Y et al 2001 Significance of coating stress on substrate bow in large area processing of MCM IEEE Trans.

Adv. Packaging 24 33–6Ye W N et al 2004 Stress-induced birefringence in silicon-on-insulator (SOI) waveguides Proc. SPIE 5357 57–66Yoshida K and Nakayama S 2001 FEM analysis of eddy currents in coated PM of surface-mounted PM SM Res. Rep.

Inform. Sci. Electr. Eng. Kyushu 6 191–6


Yoshida K et al 2001 Influence of coating of PM on eddy currents in PM of surface-mounted PM SM Trans. Inst.Electr. Eng. Japan D 121 139–40

Zhang Y and Feng Z 2000 Implementation of high order impedance boundary condition into fast multipolealgorithm for large ferrite-coated cylinder scattering problem 2000 Asia-Pacific Microwave Conf. CD-ROM(Piscataway, NJ: IEEE) pp 987–91

Biomechanics

Baroud G et al 1998 Effect of the stem coating on the postoperative stress state of the femur Biomedizin. Technik43 25–8

Biegler F B et al 1995 Effect of porous coating and loading conditions on total hip femoral stem stability J. Arthroplasty10 839–47

Borodkin J et al 1999 The influence of mechanical strain magnitude on bone adaptation to porous coated implantsIEEE Eng. Medicine Biology Soc. Conf. p 768

Borodkin J L et al 1997 Influence of mechanical strain magnitude on tissue adaptation to porous-coated implants 1997Bioeng. Conf. BED 35 (ASME) pp 499–500

Buma P et al 1997 Histological and biomechanical analysis of bone and interface reactions around hydroxyapatite-coated intramedullary implants of differ stiffness Biomater. 18 1251–60

Chen B H and Lee D J 2002 Finite element analysis of slow drug release through deformed coating film: effects ofmorphology and average thickness of coating film Int. J. Pharm. 234 25–42

Chen W P et al 1998 Effects of porous coating on the stress shielding following total hip replacement Chin. J. Med.Biol. Eng. 18 21–8

Cordaro N M et al 2001 Strain transfer between a CPC coated strain gauge and cortical bone during bending J. Biomed.Mater. Res. 58 147–55

Farina C et al 1997 Bioglass-coated alumina interbody grafts for cervical spine fusions: design, development andcharacterisation Ceram. Acta 9 5–13

Hashemi A et al 1996 Bidirectional friction study of cancellous bone-porous coated metal interface J. Biomed. Mater.Res. 33 257–67

Hefzy M S and Singh S P 1997 Comparison between two techniques for modeling interface conditions in a porouscoated hip endoprosthesis Med. Eng. Phys. 19 50–62

Huiskes R and Van Rietbergen B 1995 Preclinical testing of total hip stems. The effects of coating placement ClinicalOrthop. Relat. Res. 319 64–76

Johnson T et al 2004 Improved performance of fully coated beaded implants 7th World Biomater. Congr. (Sydney)p 1125

Ko C C et al 1995 Ingrowth rule: a relationship between tissue strain and osseointegration for porous coated implants1995 Bioeng. Conf. (Beever Creek) BED 29 (ASME) pp 481–2

Kucuk M 2001 Thermal stress analysis in the coated upper canine Math. Comput. Appl. 6 23–35Meijer G J et al 1995 The influence of a flexible coating on the bone stress around dental implants J. Oral Rehabil.

22 105–11Meijer G J et al 1995 Observations of the bone activity adjacent to unloaded dental implants coated with polyactive

or HA J. Oral Rehabilitation 22 167–74Orlik J et al 2003 On the secondary stability of coated cementless hip replacement: parameters that affected interface

strength Med. Eng. Phys. 25 825–31Punantapong B et al 2005 Evaluation of failure behaviour of coated anisotropic materials for dental implants

J. Metastable Nanocrystall. Mater. 23 23–6Schrooten J and Helsen J A 2000 Adhesion of bioactive glass coating to Ti6Al4V oral implant Biomater. 21

1461–9Schrooten J et al 1999 Adhesion of new bioactive glass coating J. Biomed. Mater. Res. 44 243–52Schrooten J et al 1999 A new adhesion test for bioactive glass coatings 25th Annual Meeting Soc. Biomater. p 423Tanimoto Y et al 2004 Stress analysis of hydroxyapatite-coated implant by finite element method-influences of

thickness and Young’s modulus of hydroxyapatite layer 7th World Biomater. Congr. (Sydney) p 1777Thompson J I et al 1999 Analysis of push-out test data based on interfacial fracture energy J. Mater. Sci. Mater. Med.

10 863–8Vaillancourt H et al 1995 Finite element analysis of crestal bone loss around porous-coated dental implants J. Appl.

Biomater. 6 267–82Vaillancourt H et al 1996 Factors affecting crestal bone loss with dental implants partially covered with a porous

coating: a finite element analysis Int. J. Oral Maxillofac. Implants 11 351–9Zhang C et al 2001 In vitro mechanical integrity of hydroxyapatite coatings on Ti-6Al-4V implants under shear loading

J. Biomed. Mater. Res. 56 342–50

976 J Mackerle

Zhang C et al 2001 Elastic and plastic behavior of plasma-sprayed hydroxyapatite coatings on a Ti-6Al-4V substrateBiomater. 22 1357–63

Material processing and machining

Attia M H and Kops L 2004 A new approach to cutting temperature prediction considering the thermal constrictionphenomenon in multi-layer coated tools CIRP Ann.—Manuf. Tech. 53 47–52

Bouzakis K D et al 1998 Experimental and FEM analysis of the fatigue behaviour of PVD coatings on HSS substratein milling CIRP Ann.—Manuf. Tech. 47 69–72

Bouzakis K D et al 1998 Fatigue prediction of thin hard coatings on the steel races of hybrid bearings used in highspeed machine tool spindles J. Tribol. ASME 120 835–42

Bouzakis K D et al 1998 Fatigue failure mechanisms of multi- and monolayer physically vapour-deposited coatingsin interrupted cutting processes Surf. Coat. Technol. 108–109 526–34

Bouzakis K D et al 1999 Quantification of properties modification and cutting performance of (Ti1−xAlx )N coatingsat elevated temperatures Surf. Coat. Technol. 120–121 34–43

Bouzakis K D et al 2001 Failure mechanisms of physically vapour deposited coated hardmetal cutting in turning Wear248 29–37

Bouzakis K D et al 2001 Improvement of PVD coated inserts cutting performance, through appropriate mechanicaltreatments of substrate and coating surface Surf. Coat. Technol. 146–147 443–50

Bouzakis K D et al 2002 Effect of the cutting edge radius and its manufacturing procedure, on the milling performanceof PVD coated cemented carbide inserts CIRP Ann.—Manuf. Tech. 51 61–4

Bouzakis K D et al 2003 Optimisation of the cutting edge roundness and its manufacturing procedures of cementedcarbide inserts, to improve milling performance after PVD coating Surf. Coat. Technol. 163–164 625–30

Bouzakis K D et al 2003 The influence of the coating thickness on its strength properties and on the milling performanceof PVD coated inserts Surf. Coat. Technol. 174–175 393–401

Bouzakis K D et al 2004 The effect of coating thickness, mechanical strength and hardness properties on the millingperformance of PVD coated cemented carbides inserts Surf. Coat. Technol. 177–178 657–64

Bouzakis K D et al 2004 Milling performance of cemented carbides inserts, coated with various thick and hard films6th Int. Conf. Mesomech. (Univerity of Patras, Greece) pp 79–85

Bouzakis K D et al 2004 Milling performance of coated inserts with variable coating thickness on their rake and flankCIRP Ann.—Manuf. Tech. 53 81–4

Bouzakis K D et al 2004 Wear development on cemented carbide inserts, coated with variable film thickness in thecutting wedge region Surf. Coat. Technol. 188–189 636–43

Buchmann M and Gadow R 2000 High speed circular microhole milling method for the determination of residualstresses in coatings and composites Ceram. Eng. Sci. Proc. 21 109–16

Fan W D et al 1995 Improvement of adhesion of diamond coatings to WC(Co) tool substrates Mater. Res. Soc. Symp.Proc. 363 163–8

Fukui H et al 2004 Cutting performance of DLC coated tools in dry machining aluminum alloys Surf. Coat. Technol.187 70–6

Fukui H et al 2004 Aluminum milling performance of DLC coated tools prepared by using a vacuum arc dischargemethod J. Japan. Soc. Tribol. 49 509–17

Hofter A et al 2004 Quenching simulation of PM coated tools Trans. Mater. Heat Treat. 25 752–7Hofter A et al 2004 Numerical heat treatment simulation of steel parts with wear resistant two phase coatings HTM—

Haerterei-Tech. Mitteil. 59 241–50Huang C H 2001 Tribology of polymer films in manufacturing PhD Thesis University of Notre DameKato T and Fujii H 2004 Temperature measurement in a solid body heated by laser beam Int. J. Mach. Tools Manuf.

44 927–31M’Saoubi R and Chandrasekaran H 2004 Investigation of the effects of tool micro-geometry and coating on

tool temperature during orthogonal turning of quenched and tempered steel Int. J. Mach. Tools Manuf. 44213–24

MacGinley T and Monaghan J 1999 Modelling the orthogonal machining process using coated carbide cutting toolsComput. Mater. Sci. 16 275–84

MacGinley T and Monaghan J 2001 Modelling the orthogonal machining process using coated cemented carbidecutting tools J. Mater. Process. Technol. 118 293–300

Monaghan J and Murphy M 1996 Analysis of the stress distribution within the layers of multi-coated forming andcutting tools Key Eng. Mater. 118–119 131–8

Nedelik J and Lux B 1999 Improved tool performance by application of heat-spreading diamond layers within amultilayered coating Int. J. Refract. Met. Hard Mater. 17 275–82


Ng E G and Aspinwall D K 2000 Hard part machining AISI H13 (approximately 50 HRC) using AMBORITE AMB90:a finite element modeling approach Indust. Diamond Rev. 60 305–10

Russell W C and Mohmand F 1998 Technology transfer issues for hard coatings in the cutting tool industry Surf.Coat. Technol. 108–109 604–11

Zhong D et al 2001 Finite element analysis of a coating architecture for glass-molding dies Surf. Coat. Technol.146–147 312–7

Zhong D et al 2003 Development of surface engineered coatings for dies used in material processing TMS AnnualMeeting (San Diego) pp 183–94

Turbines

Breitbach G and Schubert F 2004 A contribution to stress prediction in coatings for gas turbine blades Arch. Appl.Mech. 73 682–9

Chen X 2003 Failure mechanisms of thermal barrier coatings at high temperature ASME Int. Mech. Eng. Congr. MD 98(ASME) pp 159–67

Coalmer M S and Vafai K 1995 Investigation of the heat transfer characteristics of a typical annular combustionchamber of an industrial gas turbine Heat Transfer Eng. 16 17–27

Lugscheider E and Nickel R 2003 Finite element simulation of a coating formation on a turbine blade during plasmaspraying Surf. Coat. Technol. 174–175 475–81

Moriya S et al 1999 Research on the application of PSZ/Ni FGM thermal barrier coating to the combustion chamber(damage conditions of TBC and its mechanism) Mater. Sci. Forum 308–311 410–5

Nylen P et al 1999 Modeling of coating thickness, heat transfer, and fluid flow and its correlation with the thermalbarrier coating microstructure J. Therm. Spray Technol. 8 393–8

Osgerby S et al 1999 Oxidation-limited component lifetime in turbines: adhesion of coatings and oxide scales Mater.High Temp. 16 131–6

Pajari H et al 2003 Blade coating with free jet applicator: modeling and experiments TAPPI Adv. Coat. Fund. Symp.(Chicago) pp 65–82

Rettig U et al 1998 Characterization of fatigue mechanisms of thermal barrier coatings by a novel laser-based test Int.Gas Turbine Aeroengine Congr. Exhib. (Stockholm) pp GT-336

Verrilli M et al 2004 Ceramic matrix composite vane subelement testing in a gas turbine environment ASME TurboExpo 2004 (Vienna) vol 2 (ASME) pp 393–9

Other applications

Ash J T et al 2004 Shape achievement of optical membrane mirrors using coating/substrate intrinsic stressesJ. Spacecraft Rockets 41 551–7

Bertamini L et al 1995 Characterisation and modellisation of a burner rig test for thick thermal barrier coatings forautomotive applications 4th Eur. Ceram. Soc. Conf. (Riccione) pp 383–93

Cheon J S et al 2004 Evaluation of a pellet-clad mechanical interaction in mixed oxide fuels during power transientsby using axisymmetric finite element modeling Nucl. Eng. Des. 231 39–50

Christoforidis G C et al 2001 Induced voltages and currents on gas pipelines with imperfect coatings due to faults ina nearby transmission line IEEE Porto Power Tech. Proc. vol 4 (Piscataway, NJ: IEEE) pp 1–6

Christoforidis G C et al 2003 Inductive interference calculation on imperfect coated pipelines due to nearby faultedparallel transmission lines Electr. Power Syst. Res. 66 139–48

Cortes C et al 2002 On the calculation of coated fins ASME Int. Mech. Eng. Congr. Expo. HTD 372 (V 2)pp 49–53

Corvalan C M and Saita F A 1995 Blade coating on a compressible substrate Chem. Eng. Sci. 50 1769–83Crome T 1999 Reeling of pipelines with thick insulation coating, finite element analysis of local buckling Ann.

Offshore Tech. Conf. (Houston) (OCT) pp 47–55Denis A and Soba A 2003 Simulation of pellet-cladding thermomechanical interaction and fission gas release Nucl.

Eng. Des. 223 211–29Fujisawa A et al 2003 Development of glass substrates with tin oxide for A-SI solar modules 3rd World Conf. Photovolt.

Energy Conv. (Osaka) pp 1745–7Greiner M et al 1996 Legal weight truck cask response to regulatory format thermal events: Part I. Fuel cladding

7th Ann. Int. Conf. High Radioact. Waste (Las Vegas) (ASCE) pp 351–3Hejwowski T and Weronski A 2002 The effect of thermal barrier coatings on diesel engine performance Vacuum

65 427–32

978 J Mackerle

Holland D B et al 2002 Geometric scaling properties of inflatable structures for use in space solar power generation43rd Str. Str. Dyn. Mater. Conf. (AIAA) pp 507–16

Jernkvist L O 1995 Model for predicting pellet-cladding interaction-induced fuel rod failure Nucl. Eng. Des. 156393–9

Johnston J et al 2003 Structural analysis and testing of a subscale sunshield membrane layer 44th Str. Str. Dyn. Mater.Conf. (Norfolk) (AIAA) pp 3151–60

Kim B G et al 2000 Multi-layer coating of silicon carbide and pyrolytic carbon on UO2 pellets by a combustionreaction J. Nucl. Mater. 281 163–70

Kuroda M et al 2000 Influence of precipitated hydride on the fracture behavior of zircaloy fuel cladding tube J. Nucl.Sci. Technol. 37 670–5

Kuroda M et al 2001 Analysis of the fracture behavior of hydrided fuel cladding by fracture mechanics Nucl. Eng.Des. 203 185–94

Kwon Y D et al 2004 Thermo-mechanical behaviors of ceramic-coated structures in outer space using partial modeltechnique FEOFS 2003 (Sendai, Japan) (Trans. Tech.) pp 657–62

Lidbury D P G et al 2001 Key features arising from structural analysis of the NESC-1 PTS benchmark experimentInt. J. Pressure Ves. Piping 78 225–36

Lim C S et al 2000 Evaluation of technical feasibility on applying calcareous deposit coatings to ship ballast tanksCorros. Rev. 18 181–93

Lovell M R and Khonsari M M 1998 On the frictional characteristics of ball bearings coated with solid lubricantsASME/STLE Joint Tribol. Conf. (Toronto) pp 1–7

Lovell M R and Khonsari M M 1999 On the frictional characteristics of ball bearings coated with solid lubricantsJ. Tribol. ASME 121 761–7

Lovell M R et al 1996 A finite element analysis of the frictional forces between a cylindrical bearing element andMoS2 coated and uncoated surfaces Wear 194 60–70

Lovell M R et al 1996 Parameter identification of hysteresis friction for coated ball bearings based on three-dimensionalFEM analysis 1996 ASME/STLE Joint Tribol. Conf. (San Francisco) pp 1–10

Lovell M R et al 1997 Parameter identification of hysteresis friction for coated ball bearings based on three-dimensionalFEM analysis J. Tribol. ASME 119 462–70

Lovell M R et al 1997 Frictional analysis of MoS2 coated ball bearings: a three-dimensional finite element analysisJ. Tribol. ASME 119 754–63

Maher A and Hamada A A 2001 On the modelling of tubes with composite coat IMAC-XIX (Kissimmee, FL)pp 782–9

Marie S 2004 Analytical expression of the thermal stresses in a vessel or pipe with cladding submitted to any thermaltransient Int. J. Pressure Ves. Piping 81 303–12

Memari A M et al 2004 Study of the effect of near-source vertical ground motion on seismic design of precast concretecladding panels J. Architect. Eng. 10 167–84

Moinereau D et al 2001 Methodology for the pressurized thermal shock evaluation: recent improvements in FrenchRPV PTS assessment Int. J. Pressure Ves. Piping 78 69–83

Muchai J G et al 2002 Thermal-mechanical stress analysis of a PSZ coated piston through finite element techniqueCeram. Eng. Sci. Proc. 23 159–66

Muchai J G et al 2002 Thermal-mechanical effects of ceramic thermal barrier coatings on diesel engine piston Mater.Res. Soc. Symp. Proc. 697 317–22

Ness O B and Verley R 1995 Strain concentrations in pipelines with concrete coating an analytical model Proc. Int.Conf. Offshore Mech. Arctic Eng. OMAE, vol 5 (ASME) pp 507–12

Nichols M E and Darr C A 1998 Effect of weathering on the stress distribution and mechanical performance ofautomotive paint systems J. Coat. Tech. 70 141–9

Retel V et al 2004 Comparative effects of structural and material parameters variability on pellet-cladding interactionin a PWR fuel rod Nucl. Eng. Des. 228 35–46

Uwaba T and Ukai S 2002 The secondary stress analyses in the fuel pin cladding due to the swelling gradient acrossthe wall thickness J. Nucl. Mater. 305 21–8

Valenza D et al 2002 Characterisation and thermal loading of low-Z coatings for the first wall of W7-X J. Nucl. Mater.307–311 89–94

Wilmhurst S R et al 2001 Local riser impact: the effect of neoprene coatings Int. Offshore Polar Eng. Conf. (Stavanger)pp 261–7

Ying A Y and Gaizer A A 1995 The effects of imperfect insulator coatings on MHD and heat transfer in rectangularducts Fusion Eng. Des. 27 634–41

Youchison D L et al 1999 CHF comparison of an attached-fin hypervapotron and porous-coated channels 18thIEEE/NPSS Symp. Fusion Eng. pp 388–91


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