Laminate Crack Resistance via Intermediate Layer
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Solution Overview
Problem
Existing laminate manufacturing techniques fail to adequately increase the temperature at which cracks occur in spray coating films when heating the base material, limiting their application in high-temperature environments.
Innovation Solution
A method involving the formation of an intermediate layer with a thermal expansion coefficient between the base material and the spray coating film, using cold or thermal spray methods, to accumulate compressive stress and enhance adhesion, thereby increasing the temperature at which cracks occur in the spray coating film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an intermediate layer is provided to suppress crack occurrence in the spray coating film, then the temperature resistance of the laminate is improved, but the manufacturing process complexity increases
Solution Approach 1:
An intermediate layer made of metal or alloy is introduced between the base material and the spray coating film. This intermediate layer has a thermal expansion coefficient that is lower than the base material and higher than the spray coating film, serving as a stress buffer to suppress crack occurrence in the spray coating film when the laminate is heated, thereby improving temperature resistance
Solution Approach 2:
The thermal expansion coefficient parameter is strategically selected for the intermediate layer material to create a gradient between the base material and spray coating film. By controlling this physical parameter, the stress distribution during thermal cycling is optimized to prevent crack formation while maintaining structural integrity
2Temperature
If the base material is heated to higher temperatures, then the operational temperature range is expanded, but crack occurrence in the spray coating film increases
Solution Approach 1:
The intermediate layer acts as a stress buffer that absorbs thermal expansion differences between the base material and spray coating film. This mediator layer enables the laminate to withstand higher base material temperatures without causing cracks in the spray coating film, thereby expanding the operational temperature range while maintaining reliability
Solution Approach 2:
The invention utilizes controlled thermal expansion characteristics by selecting an intermediate layer material with specific thermal expansion properties. The intermediate layer's thermal expansion coefficient is positioned between that of the base material and spray coating film, creating a gradient that reduces stress concentration and prevents crack formation during high-temperature operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively increases the temperature at which cracks occur in the spray coating film, allowing for higher base material heating without film failure, and improves adhesion and heat resistance.
Implementation Method 1
when a thermal expansion coefficient of the base material is different from a thermal expansion coefficient of the spray coating film formed on the base material, if the base material is heated during use of the laminate, crack may occur in the spray coating film due to stress
Implementation Method 2
forming, on a surface of the base material while heating the base material to the temperature T0, an intermediate layer made of a material that is different from the base material and is a metal or an alloy
Implementation Method 3
by cold spray method or thermal spray method
Data Source
Figure 1
Figure 2(a)~2(e)
Figure 3
AI summary
There is provided a method of manufacturing a laminate in which a spray coating film made of a material different from a base material is formed on the base material, and the laminate in which a temperature at which the crack starts to occur on the spray coating film when heating the base material is increased to be higher than before. The method of manufacturing a laminate in which the spray coating film made of a material different from the base material is laminated on the base material, the method includes: a base material heating step S1 of heating the base material; an intermediate layer forming step S2 of forming an intermediate layer made of a material different from the base material and the spray coating film on a surface of the heated base material; and a spray coating film forming step S4 of forming the spray coating film on a surface of the intermediate layer.