A numerical study was carried out by finite element analysis (FEA) for the calculation of absolute values and through-thickness variation of residual stress originating in thermal spray coatings. The investigated deposit was an air plasma sprayed alumina coating sprayed on a carbon steel substrate previously coated with Ni20Al bond coat. Results show compressive residual in-plane stresses with linear through-thickness variation and tensile normal and shear stresses having a peak at the coating-substrate interface. The influence of deposition temperature on residual stress was also investigated. The experimental validation of the FEA model was carried out using a high-speed hole drilling technique, suitably adapted for the analysis of a multimaterial structure through FEA calculation of the required calibration coefficients. A very good agreement between simulated and measured stresses was obtained, inspire of the adopted simplification hypothesis.
Valente, T., Bartuli, C., Sebastiani, M., Casadei, F. (2004). Finite element analysis of residual stress in plasma-sprayed ceramic coatings. PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS. PART L, JOURNAL OF MATERIALS, DESIGN AND APPLICATIONS., 218(L4), 321-330 [10.1243/1464420042722318].