Due to the nature of the HVOF and other thermal spray processes, residual stress build up in thick deposits is a significant and limiting problem. The residual stress-state that evolves in a deposit is largely dependent on the thermal conditions to which the system has been subjected, and is a combination of quenching stresses, which arise during deposition, and cooling stresses, post-deposition. It follows that precise control of these phenomena is essential, if a thick deposit or one with low levels of residual stress are to be thermally sprayed. This paper applies looks at analytical and finite element techniques used to predict quenching and cooling stresses within tungsten carbide-cobalt thermally sprayed deposits. The analysis investigates and predicts the quenching and cooling stresses using improved analytical and FEA techniques by validating the models with experimental results such as X-Ray Diffraction and the Hole Drilling Method. The result of this paper is a thermo-mechanical equation for quenching stress which includes the effects of misfit strain, the Poisson’s effect, variation of coating and substrate thicknesses, thermal expansion and process temperature effects.

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