Surface treatment has become an effective method to improve corrosion resistance of magnesium alloys which are the lightest commercial structural alloys with superior specific strength and stiffness. Low pressure cold spraying is used to locally deposit aluminium on AZ31 in order to enhance general and galvanic corrosion of magnesium. This study is aimed at numerical estimation of the residual stress profile due to cold spray coating using FEM. The impact of particles on the substrate is modelled in Abaqus Explicit. The challenge of AZ31 simulations is the intrinsic yield asymmetry and anisotropy which results different behaviour of the material along different direction both in tension and compression. On the other hand, there is no precise material model capable of considering the yield asymmetry and anisotropy experienced by AZ31 in Abaqus. This paper studies the effect of anisotropy of the AZ31 on residual stress induced by cold spray. The results are compared with experimental X-Ray diffraction measurements. It is suggested that an isotropic analysis in the dominant stress direction of AZ31 may result in good estimation of the residual stress profile.

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