Systems and methods for simulating topography structures of coating materials and generating analysis report thereof

Patent metadata

Field	Value
Publication number	US-2024086585-A1
Application number	US-202318461710-A
Country	US
Kind code	A1
Filing date	Sep 6, 2023
Priority date	Sep 8, 2022
Publication date	Mar 14, 2024
Grant date	—

Abstract

Most techniques to estimate the service life of coatings are experimental in nature, cost expensive and are computationally heavy. Present disclosure provides systems and methods that predict the combined effects of crack path propagation and zones of delamination, that form on coating material and its surface due to weathering. The system of the present disclosure implemented a combined Finite Element Method (FEM) and Monte Carlo based simulation approach to capture the effects of delamination and crack propagation, respectively. The crack paths are predicted using a probabilistic model, considering crack propagation, branching, and keeping a record of crack age. Stress distribution computations are performed using FEM to understand stress concentration zones and delamination behavior with time, which is methodically also combined with the time sequence of cracking as well.

First claim

What is claimed is:

1 . A processor implemented method, comprising:
obtaining, via one or more hardware processors, a plurality of inputs pertaining to a coating material being applied on a substrate; determining, via the one or more hardware processors, one or more crack channel paths, one or more crack branching regions, and one or more crack delamination outputs associated with the coating material based on the plurality of inputs; generating, via the one or more hardware processors, a topography structure of the coating material based on the one or more crack channel paths, the one or more crack branching regions, and the one or more crack delamination outputs; and simulating, via the one or more hardware processors, the topography structure of the coating material to obtain a simulated topography output comprising an analysis report of the coating material.

2 . The processor implemented method of claim 1 , wherein the plurality of inputs comprises one or more of (i) one or more positions and one or more line directions of one or more microcrack seeds in the coating material, (ii) a weathering intensity, (iii) a dynamic material cracking and delamination energy, and (iv) one or more stress types at one or more parts of the coating material.

3 . The processor implemented method of claim 1 , wherein the one or more crack channel paths comprise (i) one or more positions associated with one or more active crack tips, (ii) a statistical distribution of one or more crack deviations, and (iii) a crack growth rate.

4 . The processor implemented method of claim 1 , wherein the one or more crack branching regions comprise a rate of crack branching occurrence, and a statistical distribution of one or more angles of crack branching.

5 . The processor implemented method of claim 1 , wherein the one or more crack delamination outputs comprise at least one of (i) a statistical distribution of stress across the coating material, (ii) a delaminated profile indicative of a shape and a curvature of the coating material when delaminated from the substrate, (iii) speed and time of a delamination associated with the coating material, and (iv) one or more boundary conditions of at least one of a stress and a strain in the coating material.

6 . The processor implemented method of claim 3 , wherein the one or more crack channel paths are determined based on one or more crack tips identified using (i) the one or more active crack tips, (ii) the statistical distribution of the one or more crack deviations, (iii) the crack growth rate, and (iv) the one or more crack branching regions, and (v) a vicinity of the one or more crack tips with reference to one or more edges and one or more crack lines.

7 . The processor implemented method of claim 4 , wherein the one or more crack branching regions are identified based on a comparison of a deflection of one or more angles of the crack branching with a pre-defined angle.

8 . The processor implemented method of claim 1 , wherein the analysis report of the coating material comprises one or more of (i) a degree of damage of the coating material due to weathering, (ii) a remaining useful life (RUL) of the coating material, (ii) an intermediate stage and one or more past stages of one or more physical properties of the coating material.

9 . A system, comprising:
a memory storing instructions; one or more communication interfaces; and one or more hardware processors coupled to the memory via the one or more communication interfaces, wherein the one or more hardware processors are configured by the instructions to: obtain a plurality of inputs pertaining to a coating material being applied on a substrate; determine one or more crack channel paths, one or more crack branching regions, and one or more crack delamination outputs associated with the coating material based on the plurality of inputs; generate a topography structure of the coating material based on the one or more crack channel paths, the one or more crack branching regions, and the one or more crack delamination outputs; and simulate the topography structure of the coating material to obtain a simulated topography output comprising an analysis report of the coating material.

10 . The system of claim 9 , wherein the plurality of inputs comprises one or more of (i) one or more positions and one or more line directions of one or more microcrack seeds in the coating material, (ii) a weathering intensity, (iii) a dynamic material cracking and delamination energy, and (iv) one or more stress types at one or more parts of the coating material.

11 . The system of claim 9 , wherein the one or more crack channel paths comprise (i) one or more positions associated with one or more active crack tips, (ii) a statistical distribution of one or more crack deviations, and (iii) a crack growth rate.

12 . The system of claim 9 , wherein the one or more crack branching regions comprise a rate of crack branching occurrence, and a statistical distribution of one or more angles of crack branching.

13 . The system of claim 9 , wherein the one or more crack delamination outputs comprise at least one of (i) a statistical distribution of stress across the coating material, (ii) a delaminated profile indicative of a shape and a curvature of the coating material when delaminated from the substrate, (iii) speed and time of a delamination associated with the coating material, and (iv) one or more boundary conditions of at least one of a stress and a strain in the coating material.

14 . The system of claim 11 , wherein the one or more crack channel paths are determined based on one or more crack tips identified using (i) the one or more active crack tips, (ii) the statistical distribution of the one or more crack deviations, (iii) the crack growth rate, and (iv) the one or more crack branching regions, and (v) a vicinity of the one or more crack tips with reference to one or more edges and one or more crack lines.

15 . The system of claim 12 , wherein the one or more crack branching regions are identified based on a comparison of a deflection of one or more angles of the crack branching with a pre-defined angle.

16 . The system of claim 9 , wherein the analysis report of the coating material comprises one or more of (i) a degree of damage of the coating material due to weathering, (ii) a remaining useful life (RUL) of the coating material, (ii) an intermediate stage and one or more past stages of one or more physical properties of the coating material.

17 . One or more non-transitory machine-readable information storage mediums comprising one or more instructions which when executed by one or more hardware processors cause:
obtaining a plurality of inputs pertaining to a coating material being applied on a substrate; determining one or more crack channel paths, one or more crack branching regions, and one or more crack delamination outputs associated with the coating material based on the plurality of inputs; generating a topography structure of the coating material based on the one or more crack channel paths, the one or more crack branching regions, and the one or more crack delamination outputs; and simulating the topography structure of the coating material to obtain a simulated topography output comprising an analysis report of the coating material.

18 . The one or more non-transitory machine-readable information storage mediums of claim 17 , wherein the plurality of inputs comprises one or more of (i) one or more positions and one or more line directions of one or more

Assignees

• Tata Consultancy Services Ltd

Inventors

• Maiti Soumyadipta
• Rai Beena
• Kausley Shankar Balajirao
• Saini Parvesh
• Bhattacharjee Suryadip
• Dhrangdhariya Priyankumar Dhirajlal

Classifications

• G06F30/20 Primary

  Design optimisation, verification or simulation (optimisation, verification or simulation of circuit designs G06F30/30) · CPC title

• G01M5/0033 Primary

  by determining damage, crack or wear · CPC title

• G06F30/23

  using finite element methods [FEM] or finite difference methods [FDM] · CPC title

• G06F2111/08

  Probabilistic or stochastic CAD · CPC title

• G06F2119/04

  Ageing analysis or optimisation against ageing · CPC title