Residual stress analysis for hvof diamalloy 1005 coating on Ti–6Al–4V alloy

HVOF coating of diamalloy 1005 (similar to Inconel 625 alloy) is considered and residual stress developed in the coating is examined. The Finite Element Model (FEM) is used to predict the residual stress while the XRD technique and the curvature method are adopted to measure the residual stress levels in the coating. The FEM simulations resemble the actual experimental conditions. The analytical approximate method also is used to determine the residual stress in the coating. It is found that FEM predictions of residual stress agree with the measurement data, provided that some small differences in the magnitude of the residual stress occurred between the predictions and the experimental data. This is attributed to the assumption of the homogeneous coating structures in the simulations. The oxide compounds are formed around the splats during in-flight, which are scattered in the coating modifying the coating structure. In addition, the approximate solution for the residual stress reasonably agrees with the predictions.