Impact stress absorption and load spreading in multi-layered erosion-resistant coatings

The development of high performance erosion-resistant coatings requires understanding of stress propagation upon particle impact. In this work, we apply finite element methodology to enhance and optimize the resistance of protective coatings to erosion by solid particles with appropriate stress management. Controlled distribution of the initial residual stress in the coating was used to counteract impact stress, while Young's modulus distribution was applied to optimize impact energy spreading throughout the coating system. Considering both tensile stress reduction and energy absorption, a multi-layer configuration with specific Young's modulus and residual stress distributions along the coating depth is suggested as an optimal coating architecture. Guidelines and design principles for erosion-resistant coating systems are discussed.