The metal finishing process of electrolytic hard chrome (EHC) plating has been identified as a source of environmental pollution in most industrialized countries like Australia, Europe and USA. The key driver for the technology replacement is that the EHC plating process uses hexavalent chromium, which is a known carcinogen. Our previous research has identified that cold spray nanostructured tungsten carbide cobalt (WC-Co) coatings can be a suitable alternative to provide a functional coating in wear applications. This work explores at another similar technology- Kinetic Metallization for deposition of WC-Co coatings. In this work, the objective is to characterize the residual stress profile of these WC-Co coatings that are deposited by the latest KM systems. These coating systems are used in critical applications such as landing gear pistons and axle journals, hydraulic rods, engine shaft journals, and numerous other external surfaces that operate under high cyclic loading conditions. As such, the residual stress developed during the KM coating process has a significant influence on the fatigue properties of the components. Thus, knowledge of stresses and their linkage with other properties and production parameters is essential for the quality control of these critical structures.

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