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Recently, copper and its alloys have been widely used as coating materials due to their high applications in industries and the medical sector. Meanwhile, it is necessary to investigate several stresses induced in such coatings, especially residual stress (RS). Furthermore, this RS can influence the integrity of a coating or repair. The RS is favourable for fatigue life, fatigue strength and resistance to crack under environmental assistance. Meanwhile, the cold spray additive manufacturing approach (CSAM) has been widely adopted for successful metallic coating. The deposition phenomenon is due to the high-velocity impact with a high strain rate that introduces different stresses in the coating and substrate. In this study, both experimental and numerical approaches were adopted to investigate the RS in coating. A finite element approach called Abaqus/Explicit has been used to validate the residual stress under high-velocity impact. The experimental techniques, i.e. X-ray diffraction, scanning electron microscopy, Debye-Scherrer μ-X360n analyser have used to investigate the deposition of cold spray. Numerical output gives minute deviation of RS from the experimental one. It has been found that sufficient RS is induced to enhance the coating life used for several engineering and medical aspects along with improved fatigue life and strength.

Residual stress investigation in the metallic coating approach of micro-sized particles on the substrate: cold spray additive manufacturing