Determination of residual stresses in thermal and cold sprayed coatings by the hole-drilling method

Residual stresses in most coatings have a significant influence on adhesion, on mechanical properties and on tribological performance. Residual stress can not be measured directly, rather strain is measured and stress is calculated. In this study residual stresses were investigated in thick thermal Ni95Al5. and cold sprayed Ni, Cu, NiZn, AlZn powder coatings using the semi-destructive hole-drilling and layer growing curvature methods. Residual stresses obtained for the thermal spray coating were compressive and with a relatively large deviation of the results indicating the nonuniformity of residual stress. Cold sprayed coatings have more uniform structure than thermal sprayed coatings. Residual stresses were compressive, and results obtained by hole-drilling and curvature method were comparable.