An analytical model for predicting residual stresses in multiple layers by plasma cladding process

An analytical model is developed to predict residual stresses formed during plasma cladding process. This is based on the force and moment balances and misfit strain caused by differential coefficient of thermal expansion (CTE) of substrate and cladding layers during cooling. The model can be implemented by a simple programming. Residual stresses can be predicted from a knowledge of material properties, temperature of substrate and layers and specimen dimensions. Residual stresses are calculated after each layer rather than as a whole. Specific results can be obtained for the distribution of residual stresses within Co-based layers system. The effect of temperature of substrate and layers, the number of layers, the curvature of a composite beam on the residual stresses are discussed. It has been found that the residual stresses decrease with the increase of preheating temperature of substrate and inter-layer temperature of layers. The curvature increase with increasing layer number.