In this paper, a preliminary analysis on the residual stress evolution of cold-sprayed coatings taking copper coating as an example was performed. An integrated frame of calculation was proposed based on the simulation results obtained from the developed thermo-mechanically coupled Eulerian model. In a single Cu splat, the residual stress appears to be large tensile stress near the surrounding area of the interface and be small tensile stress at the bottom. In single pass Cu coating, the residual stress is variable and there exists not only compressive stress but also tensile stress. When the impacting velocity changes, the resultant residual stresses also vary in both cases. The present simulated results were related to the reported experiments by others, while there is much difference.

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