On the evaluation of residual stress and mechanical properties of FeCrBSi coatings by nanoindentation

In this paper, the residual stress in the plasma-sprayed FeCrBSi coating was determined by nanoindentation and X-ray diffraction (XRD). The XRD results showed that tensile residual stress was generated in the FeCrBSi coating, and the through-thickness values range between 40 MPa and 112 MPa. The residual stress measured by nanoindentation is 753 MPa. The difference between the XRD and nanoindentation results was discussed. It is found that the factors limiting the nanoindentation measurement of residual stress include the ‘sink-in’ deformation around the indenter, the roughness of the FeCrBSi coating, and the use of reference sample without residual stress. The above three factors lead to the over-prediction of residual stress by nanoindentation.

► Ni/Al coating can reduce the mismatch degree between the coating and substrate.
► No obvious pile-up is observed for the nanoindents of the FeCrBSi coating.
► The higher the tensile residual stress, the lower the hardness and elastic modulus.