Experimental and numerical study of residual stress evolution in cold spray coating

In this paper the residual stress evolution during cold spray coating process has been studied through experimental measurements and numerical simulations performed on several series of samples coated using different spray process parameters. A detailed finite element (FE) analysis of the process has been developed to calculate the stresses induced through impacts and then the annealing effect has been taken into account through an analytical model. The results of the experiments and numerical-analytical approach confirm the considerable effect of annealing on the eventual stress distribution in the coated samples.