The aim of this work is to develop a finite element model that predicts the residual stresses in plasma sprayed parts formed on conical mandrels and removed by various means. The theoretical analyses and mathematical models are confirmed by X-ray diffraction measurements on plasma-sprayed zirconia samples freed from shaped mandrels by means of cooling, melting, and chemical dissolution. Based on test results, the mandrel-cooling removal method produced the highest internal stresses. Paper includes a German-language abstract.

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