Coating thickness effect on stress distribution of coated cylinder head considering residual stress

This paper presents the coating thickness effect on the stress distribution of a coated cylinder head. A typical thermal barrier coating was applied on a diesel engine cylinder head. Thus, the residual stress which occurred during the plasma thermal spraying was also considered. The coating system consisted of two layers a metallic bond coat and a ceramic top coat. The bond coat thickness is considered as 50 to 250 µm and the top coat thickness was considered as 200 to 800 µm. The stress distribution was found by the finite element analysis using the ABAQUS software. Then, stress distributions were compared for various coating thicknesses. Finally, optimized values for each layer are suggested.