Residual stress development in cold sprayed Al, Cu and Ti coatings

Tomi Suhonen (Corresponding Author), Tommi Varis, Sergi Dosta, Marc Torrell, Josep María Guilemany

    Research output: Contribution to journalArticleScientificpeer-review

    144 Citations (Scopus)


    Residual stresses play an important role in the formation and performance of thermal spray coatings. A curvature-based approach where the substrate–coating system deflection and temperature are monitored throughout the coating deposition process was used to determine residual stress formation during cold spray deposition of Al, Cu and Ti coatings. The effect of substrate material (carbon steel, stainless steel and aluminium) and substrate pre-treatment (normal grit blasting, grit blasting with the cold spray system and grinding for carbon steel substrate) were studied for all coating materials with optimized deposition parameters. Mainly compressive stresses were expected because of the nature of cold spraying, but also neutral as well as tensile stresses were formed for studied coatings. The magnitudes of the residual stresses were mainly dependent on the substrate/coating material combination, but the surface preparation was also found to have an effect on the final stress stage of the coating.
    Original languageEnglish
    Pages (from-to)6329-6337
    JournalActa Materialia
    Issue number17
    Publication statusPublished - 2013
    MoE publication typeA1 Journal article-refereed


    • cold spraying
    • residual stresses
    • aluminium
    • copper
    • titanium
    • ProperTune


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