Modelling the damage tolerance of Cr2O3-based thermal sprayed coatings

An approach of using multiscale material models to design chromium oxide-based coatings with increased damage tolerance is presented and compared to experimental test results. Models were created from real HVOF and plasma sprayed Cr₂O₃ coating microstructures and its phase specific mechanical properties. This model was then semi-synthetically modified to include lamellar shaped metallic inclusions (different metals with different amounts and size distributions) aiming to increase the ductility without losing the impact or abrasive wear resistance. Based on the simulation results powders with different amounts of metallic inclusions were manufactured, deposited and experimentally tested. Increased ductility was observed without the reduction of hardness or abrasive wear resistance.