Residual stress in thermally sprayed coatings is known to cause a range of problems, notably debonding, cracking, and spallation. The focus in this paper is on the development of simple analytical models for the prediction of residual stress that arise from spraying a steel-alloy coating onto a copper-alloy substrate. This is a material combination that has been used recently to enhance the thermal and mechanical efficiency of the pressure die casting process although problems with debonding have been reported in the literature. Three analytical models are developed and investigated, where each represent combinations of assumptions for coating and substrate material behaviours during coating manufacture. The sensitivity of these combinations on residual stress, developed for a range of process parameters (deposited layer thickness, interval of layer deposition and the number of layers in a coating, i.e. block deposition versus multi-layer deposition for a desired coating thickness) is recorded. In agreement with experimental and finite-element modelling results from a previous study, the results from all the three models assessed in the current study indicate a progressive change in average interfacial residual stress from compressive towards tensile with an increase in the thickness of the deposited layer; and a tensile interfacial stress in a two-layer coating, which increases with an increase in the interval of deposition between the two layers. The observations from the results suggest an increase in potential for coating debonding with an increase in both deposited layer thickness and layer deposition interval. The results further suggest higher potential for coating debonding with block deposition compared with multi-layer deposition for a desired coating thickness. In terms of stress magnitudes, the model that performs best is one where the assumption that a currently deposited coating layer yields during its quenching phase and adopts elastic behaviour afterwards; and the strain generated in the substrate during the quenching phase is from thermal effect only while in the other phases afterwards, is from both thermal and elastic effects.
