Residual stresses analysis of cold sprayed coatings by numerical simulation

In this paper, we performed a comprehensive analysis on the residual stress evolution of cold sprayed coatings taking copper coating as an example. An integrated frame of calculation was proposed based on the numerical modeling results obtained from the developed thermo-mechanically coupled Eulerian model. The results show that the coating presents a little tensile stress compared to the compressive stress in the substrate close to the coating. The through-coating-thickness stress also changes from compressive to tensile. When the impacting conditions (i.e. velocity and temperature) change, the resultant residual stresses also vary. The simulated results were finally related to the reported experiments. It seems that the residual stresses under some conditions could be larger than the coating/substrate adhesion strength, and thus causes the peeling of coating in a compressive way.