Residual Stresses in Thermal Spray Coatings and Their Effect on Interfacial Adhesion: A Review of Recent Work

An overview is presented of the development of residual stresses in thermal spray coatings and their ef-fects on interfacial debonding. The main experimental techniques for measurement of residual stresse are briefly described, with particular attention given to the method of continuous curvature monitoring. Boundary conditions satisfied by all residual stress distributions are identified and expressions derived for the curvatures and stress distributions arising from a uniform misfit strain between coating and sub-strate.It is noted that stress distributions in thick coatings rarely correspond to the imposition of such a uniform misfit strain, so that recourse to numerical methods becomes essential for quantitative predic-tion of stress distributions. Relationships are presented between residual stresses and corresponding strain energy release rates during interfacial debonding. The effect on this of superimposing stresses from an externally applied load is outlined. The initiation of debonding is then considered, covering edge effects and other geometrical considerations. Finally, some specific case histories are briefly outlined to illustrate how the various theoretical concepts involved relate to industrial practice.

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