In situ measurement of residual stresses and elastic moduli in thermal sprayed coatings part 2: Processing effects on properties of Mo coatings

Residual stresses and mechanical properties of plasma sprayed coatings play a critical role in their functionality and lifetime. These can be influenced by modification of spraying parameters. Among the most important parameters are the deposition temperature, particle temperature and velocity and deposition rate. Using the in situ thermo-elastic curvature method described in Part 1 of this paper, their effects on the stresses and moduli of plasma sprayed molybdenum were investigated. The results for quenching, thermal, and residual stresses as well as Young's moduli are presented and discussed with respect to the spraying parameters and material properties. The most influential factors are determined and means for property modification using this technique are described. The development of the in situ approach along with the ability to measure elastic modulus and residual stresses enables capturing the quality and integrity of the deposit. This will allow for future downstream process control based on materials characteristics. Published by Elsevier Science Ltd on behalf of Acta Materialia Inc.