Residual stresses exert profound influence on the longevity of parts with thermal spray coatings. The distribution and value of the residual stresses depend on method of coating deposition, composition of the applied material, parameters of thermal spraying and methods of post-treatment. Therefore, the study of the influence of the various technological factors on the residual stresses in the plasma spray coatings is very important. Due to heterogeneity of the coating, residual stresses can be determined only by the experimentation by using new methods which take into consideration real values of elastic characteristics and density of elementary layers. Methods and formulas for the calculations of the residual stresses in coatings deposited on bars, rings, discs, cylinders are presented. Experimental results for the various thermal spray coatings are also shown. These results can be used for the optimization of coating deposition and would supplement the existing database.

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