Characterisation of the Residual Stresses in HVOF WC-Co Coatings and Substrates
Residual strains and stresses associated with the processing steps of the industrial high-velocity oxygen-fuel (HVOF) thermal spray technique, was non-destructively characterised in both the coatings and substrates. A range of substrates, having coefficients of thermal expansion different to that of the as-coated WC-Co material, have been considered to assess the potential role of the thermal misfit associated with the coating procedure. Surface and depth resolved studies of the in-plane and normal components of residual strains have been investigated by exploiting the penetrating capabilities of high energy synchrotron X-rays in conjunction with micron sized gauge volumes to enable strain gradient determination with high positional resolution. Results reveal the presence of large residual strain/stress mismatches at the interface region in all the substrate materials, whereas the strains/stresses in the as-coated material are small, seemingly independent of the substrate material. The different contributions due to the HVOF process are qualitatively assessed in terms of an eigenstrains (plastic deformation) approach.