Quasi-static, cyclic and fracture characteristics of thermal sprayed AlSi cylinder bore

铸铝气缸体取代了铸铁气缸体，重量减轻了40%。为了达到内孔的耐磨性，通常在气缸内部使用2毫米厚的铸铁衬里。最近，钢铁粉末热喷涂层通过在气缸孔和活塞之间提供了200微米厚的界面，提供了一种无衬套气缸，进一步减轻了重量。然而，涂层的特征、其性能、结合机制以及钢涂层/铝基材的界面特征和性能尚未获得和/或被很好地理解。这些特性在计算机辅助设计(CAE)和集成计算材料工程(ICME)中至关重要。在本项目中，将研究热喷涂圆柱体的力学行为。本研究将确定涂层、基材和界面的微观结构特征，并将获得涂层、基材和基材在准静态和循环载荷下的力学性能。将研究涂层的潜在失效机制，包括分层和/或开裂。这项研究将建立涂层微观结构、热喷涂工艺和涂层性能之间的联系。

Cast aluminum cylinder blocks have replaced cast iron blocks to gain a 40% reduction in weight. To attain wear resistance at the bore, 2-mm thick cast iron liners are commonly used inside the cylinder. Recently, thermal spray coating of iron/steel powder has offered a liner-less cylinder by providing a 200-micrometer thick interface between the cylinder bore and the piston, providing a further reduction of weight. However, the characteristics of the coating, its properties, bonding mechanisms, and steel coating/aluminum substrate interface characteristics and properties are not available and/or well understood. These properties are of paramount importance in computer aided design (CAE), and integrated computational materials engineering (ICME). In this project, the mechanical behavior of thermal spray coated cylinders will be studied. This study will identify the microstructural characteristics of the coating, substrate, and interface; and will obtain the mechanical properties of the coating, interface and substrate under quasi-static and cyclic load. Potential failure mechanisms of the coating including delamination and/or cracking will be studied. The study will establish a link between coating microstructure, thermal spray process, and coating properties.