Clarksean and Associates proposes to analyze the cracking of arresting hooks that occurs during the manufacturing process. The analysis process will consider the hardface coating, fusing,and heat treatment of the arresting hooks. The modeling approach uses separate finite element software packages to analyze the thermal (FIDAP) and residual stress formation (NIKE3D). A unique one-dimensional surface element will be developed that can be used for the analysis of all processing steps, thermal or stress related. The innovative surface element interfaces with each of the analysis packages. The one-dimensional surface element models the spray deposition, heat transfer, and residual stress levels in a manner that requires less memory and computational time. Phase I will demonstrate that the proposed modeling approach is capable of modeling all relevant steps of the manufacturing process. Technical objectives of Phase I include the development o the one-dimensional surface element, implementation of the stress model, the integration of the thermal and stress analyses, and the analysis of process steps. Meeting these objectives results in a smooth transition to refinements in the models and improvements during the manufacturing process in Phase II.
