In order to determine residual stresses in industrial plasmasprayed coatings, a rather simple apparatus, which monitors the curvature of a beam substrate during the deposition process, has been developed. The experimental set-up consists of a water-cooled rotating cylinder, holding an initially plane substrate, whose curvature is continuously measured using a contacting displacement sensor disposed into the cylinder. The combination of the plasma gun translation and the cylinder rotation allows to reach industrial spraying velocities. Liquid argon cryogenic system is used to control the substrate temperature from about 50°C to more than 300°C independently from the process velocity. A typical recording is analyzed thoroughly and a theoretical approach to residual stress calculation discussed. This method is applied to partially stabilized zirconia coatings performed onto stainless steel substrates for spraying temperatures between 80°C and 210°C.

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