Effect of micro-droplets on the local residual stress field in CAE-PVD thin coatings

► Residual stress measured in the very proximity of micro-droplets on a CrN PVD coating ► Higher surface compressive stress and reduced depth-gradient close to droplets ► Metal droplets induce coarse-grain growth and suppress stress relaxation mechanisms. ► Observed stress profiles correlated to microstructural modifications due to the droplet ► The influence of the modified stress field on in-service behavior was evaluated.