GOALI: Debonding of Interfaces in Thermal Spray Coatings

该学术联络机会奖（GOALI）将支持那些将贡献与制造工艺相关的新知识的研究，这些研究将推动科学进步，促进国家健康和繁荣。该研究项目研究热喷涂涂层，这是一层薄薄的金属，被熔化并喷涂到表面上，以提高零件或组件的耐久性和性能。这些涂层具有许多优点和应用，特别是在汽车工业中。热喷涂涂料有可能取代发动机中的铅基衬垫和铬基电镀材料。然而，为了将这项技术推向商业应用，需要有关涂层性能及其与加工条件的联系的基础科学知识。该奖项支持基础研究，为热喷涂涂料的最佳设计和制造提供所需的知识。从这项研究中获得的新知识将使涂料的设计适用于各种应用，降低成本，重量，以及对当前技术的环境影响。这项工作是与工业伙伴菲亚特克莱斯勒汽车公司和桑迪亚国家实验室合作完成的，进一步增强了研究的经济影响。这个项目的目标是发现关于热喷涂涂层在建筑系统中分层的基本知识。从新的实验见解的结果将用于制定一个新的模型来预测热喷涂涂层的分层。将开发一种基于断裂力学的模型，并对微观结构进行统计描述，用于预测热喷涂涂层的剥离。研究人员试图量化粘附强度，涂层本身的疲劳寿命，以及从涂层表面开始涂层分层所需的应力。大学-工业-国家实验室合作将为参与研究的学生提供独特的能力和宝贵的教育经验。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

This Grant Opportunities for Academic Liaison with Industry (GOALI) award will support research that will contribute new knowledge related to a manufacturing process, which will advance the progress of science and enhance national health and prosperity. This research program studies thermal spray coatings, which are a thin layer of metal that is melted and sprayed onto a surface in order to improve the durability and performance of the part or component. These coatings have numerous benefits and applications, in particular in the automotive industry. Thermal spray coatings have the potential to replace lead-based liners in engines and chromium-based plating materials used in a number of applications. To move this technology to commercial applications, however, fundamental scientific knowledge about the coating performance and its linkages to processing conditions is needed. This GOALI award supports fundamental research to provide the needed knowledge for the optimum design and manufacture of thermal spray coatings. The new knowledge which will result from this research will enable the design of coatings for a variety of applications, reducing cost, weight, and environmental impact over current technologies. This work is performed in collaboration with an industrial partner, Fiat Chrysler Automotive, and Sandia National Laboratories, further enhancing the economic impact of the research. The goal of this project is to discover fundamental knowledge pertaining to the delamination of thermal spray coatings in built-up systems. Results from novel experimental insights will be used to formulate a new model to predict delamination of thermal spray coatings. A fracture mechanics-based model informed with a statistical description of the microstructure will be developed and used to predict the debonding of thermal spray coatings. The researchers seek to quantify the strength of adhesion, the fatigue life of the coating itself, and the stresses necessary to initiate delamination of the coating from coated surfaces. The university-industry-national laboratory collaboration will provide unique capabilities as well as valuable educational experiences for the students involved in the research.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.