New technologies as Near Net-Shape Spray Forming offer good possibilities to obtain quickly and easily nozzle type refractory components. Excessive material utilisation and laborious machining can be avoided. Cylindrical shape components have been obtained by plasma spraying of yttria partially stabilized zirconia powder on a preshaped mandrel which was subsequently removed. Residual stress analysis through the coatings has been performed using three evaluation methods. A mathematical model able to predict the levels of residual stress is presented and used. A finite element analysis is developed in order to calculate the residual stress field in the near-net shape formed coatings. The validation of the theoretical analysis and mathematical models were performed by neutron diffraction measurements. The experimental results are in good agreement with those obtained by analytical methods and reveal low levels of residual stresses within the sprayed coatings.

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