Residual stress determination in plasma sprayed Al₂O₃ coatings

Residual stress is a problem which could reduce the lifetime of plasma sprayed coatings. So it is necessary to find the relationship between plasma spray parameters and residual stress. In this study, a plasma spraying technique was used to deposit Al₂O₃ coatings on stainless steel substrates under different spraying parameters. The residual stresses were determined by an X-ray diffraction method. Furthermore, surface roughness and porosity of the plasma sprayed Al₂O₃ coatings were measured.