Theoretical prediction of residual stresses induced by cold spray with experimental validation

Dibakor Boruah, Xiang Zhang, Matthew Doré

Research output: Contribution to journalArticle

4 Citations (Scopus)
55 Downloads (Pure)


Purpose: The purpose of this paper is to develop a simple analytical model for predicting the through-thickness distribution of residual stresses in a cold spray (CS) deposit-substrate assembly. Design/methodology/approach: Layer-by-layer build-up of residual stresses induced by both the peening dominant and thermal mismatch dominant CS processes, taking into account the force and moment equilibrium requirements. The proposed model has been validated with the neutron diffraction measurements, taken from the published literature for different combinations of deposit-substrate assemblies comprising Cu, Mg, Ti, Al and Al alloys. Findings: Through a parametric study, the influence of geometrical variables (number of layers, substrate height and individual layer height) on the through-thickness residual stress distribution and magnitude are elucidated. Both the number of deposited layers and substrate height affect residual stress magnitude, whereas the individual layer height has little effect. A good agreement has been achieved between the experimentally measured stress distributions and predictions by the proposed model. Originality/value: The proposed model provides a more thorough explanation of residual stress development mechanisms by the CS process along with mathematical representation. Comparing to existing analytical and finite element methods, it provides a quicker estimation of the residual stress distribution and magnitude. This paper provides comparisons and contrast of the two different residual stress mechanisms: the peening dominant and the thermal mismatch dominant. The proposed model allows parametric studies of geometric variables, and can potentially contribute to CS process optimisation aiming at residual stress control.

Original languageEnglish
Pages (from-to)599-616
Number of pages18
JournalMultidiscipline Modeling in Materials and Structures
Issue number3
Early online date5 Apr 2019
Publication statusPublished - 7 May 2019

Bibliographical note

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  • Residual Stress
  • Analytical Modelling
  • Cold Spray
  • Additive Manufacturing
  • Coatings
  • Repairs
  • Thermal spray
  • Analytical prediction
  • Aluminium alloy
  • Magnesium
  • Titanium
  • Neutron diffraction

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  • Activities

    • 1 Participation in conference

    10th European Conference on Residual Stresses

    Dibakor Boruah (Speaker)
    13 Sep 2018

    Activity: Participating in or organising an eventParticipation in conference

    Research Output

    • 4 Citations
    • 2 Article
    • 1 Conference proceeding

    Experimental evaluation of interfacial adhesion strength of cold sprayed Ti-6Al-4V thick coatings using an adhesive-free test method

    Boruah, D., Robinson, B., London, T., Wu, H., de Villiers-Lovelock, H., McNutt, P., Doré, M. & Zhang, X., 15 Jan 2020, In : Surface and Coatings Technology. 381, 15 p., 125130.

    Research output: Contribution to journalArticle

  • Evaluation of residual stresses induced by cold spraying of Ti-6Al-4V on Ti-6Al-4V substrates

    Boruah, D., Ahmad, B., Lee, T. L., Kabra, S., Syed, A., McNutt, P., Doré, M. & Zhang, X., 25 Sep 2019, In : Surface and Coatings Technology. 374, p. 591-602 12 p.

    Research output: Contribution to journalArticle

    Open Access
  • 11 Citations (Scopus)
    9 Downloads (Pure)

    An analytical method for predicting residual stress distribution in selective laser melted/sintered alloys

    Boruah, D., Zhang, X. & Doré, M., 5 Oct 2018, European Conference on Residual Stresses 2018 (ECRS-10): Materials Research Proceedings . Seefeldt, M. (ed.). Materials Research Forum LLC, Vol. 6. p. 283-288 6 p.

    Research output: Chapter in Book/Report/Conference proceedingConference proceeding

    Open Access
  • 64 Downloads (Pure)


    Best PhD Student 2019

    Dibakor Boruah (Recipient), 2 Jul 2019

    Prize: National/international honour

  • TWI Industrial Impact Award (Winner) 2019

    Dibakor Boruah (Recipient), 3 Jul 2019

    Prize: Prize (including medals and awards)


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