Analysis of Thermal History and Residual Stress in Cold-Sprayed Coatings

Residual stress in coatings has significant effect on their performance. In cold-sprayed coatings, in which particles impact the substrate at high velocity in solid state, in-plane residual stresses are usually conceived to be compressive. In this research, analysis of residual stresses in cold-sprayed deposits is performed by analytical and numerical modeling. The influence of various parameters such as the dimensions and elastic properties of the coating and the substrate on the residual stress are analyzed. In addition, the amount of heat input as a key parameter in the build-up of the residual stress is examined. It has been found that the heat input and the associated thermal history have a major influence on the final distortion and the residual stress, to an extent that the in-plane stress can in some cases change from compressive to tensile. Based on these results, a simple model is put forward for the prediction of the final state of the stress and distortion in cold-sprayed flat components.