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The residual stress profiles in Cu and Al coatings sprayed using kinetic metallization to thickness of 2 mm have been studied. Due to specific parameters of the cold-spray process and particular combination of materials, coatings and substrates, the residual stresses are low with magnitudes of the order of a few tens of MPa. This poses challenges on accuracy and resolution when measuring through-thickness stress distributions. Three experimental techniques - neutron diffraction, X-ray diffraction and a slitting method- were used to measure through thickness stress distributions in the substrate-coating systems. All three techniques demonstrated acceptable accuracy and resolutions suitable for analyzing stress profiles. Advantages and disadvantages of each technique are discussed.

Stress Profiling in Cold-Spray Coatings by Different Experimental Techniques: Neutron Diffraction, X-Ray Diffraction and Slitting Method