Effect of particle impact on residual stress development in HVOF sprayed coatings

The application of thick high-velocity oxyfuel (HVOF) coatings on metallic parts has been widely accepted as a solution to improve their wear properties. The adherence of these coatings to the substrate is strongly influenced by the residual stresses generated during the coating deposition process. In an HVOF spraying process, due to the relatively low processing temperature, significant peening stresses are generated during impact of molten and semimolten particles on the substrate. At present, finite-element (FE) models of residual stress generation for the HVOF process are not available due to the increased complexities in modeling the stresses generated due to the particle impact. In this work, an explicit FE analysis is carried out to study the effect of molten particle impingement using deposition of an HVOF sprayed copper coating on a copper substrate as an example system. The results from the analysis are subsequently used in a thermomechanical FE model to allow the development of the residual stresses in these coatings to be modeled.