Design and optimization of coating structure for plasma sprayed self-healing MgO coating via finite element method

The necessary conditions for fabricating plasma sprayed self-healing MgO coating with excellent performance is to find an optimized coating structure with suitable thickness of each layer, self-healing agent content and low residual stress. This paper discusses the design and optimization of a suitable coating structure for the self healing MgO coating prepared by atmospheric plasma spraying (APS) using the finite element method (FEM). Through the stress analysis of the special points of the coating and interface, a suitable coating structure is designed. The optimization of the coating structure mainly includes the thickness of the coating, the analysis of the composition of the coating and the analysis of the effect of convective heat transfer coefficient (CHTC) on the residual stress of the coating. The failure modes are predicted. The spray thickness of each layer and the fabrication method in the coating cooling process are optimized.