Residual Stresses Distribution through Thick HVOF Sprayed Inconel 718 Coatings

Residual stress buildup in thick thermal spray coatings is a property of concern. The adhesion of these coatings to the substrate is influenced by residual stresses that are generated during the coating deposition process. In the HVOF spray process, significant peening stresses are generated during the impact of semimolten particles on the substrate. The combination of these peening stresses together with quenching and thermal mismatch stresses that arise after deposition can be of significant importance. Both numerical method, i.e., Finite Element Method (FEM), and experimental methods, i.e., the Modified Layer Removal Method (MLRM) and Neutron Diffraction, to calculate peening and quenching stresses have been utilized in this work. The investigation was performed on thick Inconel 718 coatings on Inconel 718 substrates. Combined, these numerical and experimental techniques yield a deeper understanding of residual stress formation in the HVOF process and thus a tool for process optimization. The relationship between the stress state and deposit/substrate thickness ratio is given particular interest.