Determination of the elastic modulus of wire arc sprayed alloy 625 using experimental, analytical, and numerical simulations

In the present study, the mechanical properties of thermal sprayed wire arc coating of super alloy 625 were investigated. This work is a continuation of previous study on microstructural characterization of wire arc sprayed alloy 625. The elastic modulus of the coating was experimentally determined using Knoop indentation, resonant frequency, tensile test, three-point bending test, and nano-indentation. In addition, the elastic modulus was calculated using numerical simulations and by use of available analytical methods. Thermally sprayed depositions exhibit anisotropic structure resulting in different mechanical properties in the transverse and longitudinal directions. Some of the techniques used in this study are only capable of determining properties in one direction. However, Knoop indentation and image based finite element analysis can measure and predict the elastic modulus in both directions. Comparison of the results obtained from the analytical models, numerical simulations, and experimental tests lead to better understand of the capabilities and accuracy of each method in prediction and measurement of mechanical properties of thermal spray coating structures. •Thermal spray deposition of superalloys•Experimental investigation on mechanical properties of metallic coatings•Mechanical properties of coatings in terms of microstructural characteristics•Image based finite element analysis to estimate elastic modulus of coatings•Elastic modulus of coatings from nano-indentation test