COMPLAS 2023

Modeling of the Compaction Shot-Peening Process of an Al Multiparticulate Coating

  • Eschard, Louise (Arts et Métiers Institute of Technology)
  • Kubler, Régis (Arts et Métiers Institute of Technology)
  • Barrallier, Laurent (Arts et Métiers Institute of Technology)
  • Deloye, Fanny (IRT M2P)
  • Gani, Léa (Safran Aircraft Engines)

Please login to view abstract download link

To ensure the corrosion protection of some aircraft engines parts, a coating made of aluminium particles incorporated in a sol-gel matrix is deposited on a steel substrate. As a sacrificial anode, the coating will corrode in place of the substrate. One of the conditions to trigger this protection, is the electrical conductivity of the coating and so its continuity through the aluminium particles. However, due to the curing of the coating after its application, cracks and porosities are formed and need to be closed thanks to a compaction shot-peening process. The process consists in projecting ceramic shots at the coating surface, rearranging locally the particles and modifying their morphologies through plastic deformation. The aim of this study is to simulate the process in order to look deeper into the compaction mechanisms and understand the development of mechanical fields such as the plastic deformation along the coating depth. A first single shot model, using MPFEM (MultiParticle Finite Element Modeling) [1], is developed to analyze the influence of the process parameters (shot’s velocity and size, impact angle) on the compacted coating (thickness, gradient of mechanical fields, morphology and rearrangement). The study is then extended to multiple shots with a representative coverage to understand the compaction mechanisms. The model is then simplified in a continuous equivalent material model considering internal variables, such as relative density, built as the approach developed in powder compaction simulations [2]. The identification of the model parameters is realized based on the MPFEM model and the results are compared to available experimental data. [1] A. T. Procopio et A. Zavaliangos, “Simulation of multi-axial compaction of granular media from loose to high relative densities,” Journal of the Mechanics and Physics of Solids, vol. 53, p.1523–1551, 2005. [2] D. C. Drucker, R. E. Gibson et D. J. Henkel, “Soil mechanics and work-hardening theories of plasticity,” Transactions of the American Society of Civil Engineers, vol. 122, p. 338–346, 1957.