TY - JOUR

T1 - An image morphing method for 3D reconstruction and FE-analysis of pore networks in thermal spray coatings

AU - Wiederkehr, Thomas

AU - Klusemann, Benjamin

AU - Gies, D.

AU - Müller, Heinrich

AU - Svendsen, Bob

PY - 2010/2

Y1 - 2010/2

N2 - Using thermal spraying various surface coatings consisting of different material compositions can be manufactured. Besides different solid phases the resulting coating microstructure often contains a non-negligible amount of pores altering their mechanical properties. A common practice to analyze the porosity and composition of a coating is to create cross section images using standard light microscopy equipment or a scanning electron microscope. In this paper a method is presented to construct a three-dimensional multiphase model of the coating from a number of such cross section images by means of an image morphing technique. The resulting model can then be used for visualization purposes or further analysis e.g. within a finite element simulation. The described method has been applied to the construction of a finite element model of a porous coating sample which is used in a compaction simulation to determine its behavior in a rolling process. The required cross section images were obtained using a successive grinding and microscopy procedure. The material behavior of the porous material is modeled by using a modified Johnson-Cook material model formulation for an elasto-viscoplastic material. Comparison of 2D and 3D-simulation results are shown.

AB - Using thermal spraying various surface coatings consisting of different material compositions can be manufactured. Besides different solid phases the resulting coating microstructure often contains a non-negligible amount of pores altering their mechanical properties. A common practice to analyze the porosity and composition of a coating is to create cross section images using standard light microscopy equipment or a scanning electron microscope. In this paper a method is presented to construct a three-dimensional multiphase model of the coating from a number of such cross section images by means of an image morphing technique. The resulting model can then be used for visualization purposes or further analysis e.g. within a finite element simulation. The described method has been applied to the construction of a finite element model of a porous coating sample which is used in a compaction simulation to determine its behavior in a rolling process. The required cross section images were obtained using a successive grinding and microscopy procedure. The material behavior of the porous material is modeled by using a modified Johnson-Cook material model formulation for an elasto-viscoplastic material. Comparison of 2D and 3D-simulation results are shown.

KW - Engineering

KW - morphing

KW - 3D-Volume reconstruction

KW - thermal spraying

KW - pore distribution

KW - Image processing

KW - FEM

UR - http://www.scopus.com/inward/record.url?scp=74149085524&partnerID=8YFLogxK

UR - https://www.mendeley.com/catalogue/5ee3abd2-cdb7-3cc1-97cf-6e7bc0532a10/

U2 - 10.1016/j.commatsci.2009.11.019

DO - 10.1016/j.commatsci.2009.11.019

M3 - Journal articles

AN - SCOPUS:74149085524

VL - 47

SP - 881

EP - 889

JO - Computational Materials Science

JF - Computational Materials Science

SN - 0927-0256

IS - 4

ER -