Evaluation of residual stress in thick metallic coatings using the combination of hole drilling and micro-indentation methods

Abba A. Abubakar*, Akeem Yusuf Adesina, Abul Fazal M. Arif, Jafar Albinmousa, Khaled S. Al-Athel, S. Sohail Akhtar*

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

6 Scopus citations


Plasma spraying is commonly used to deposit thick metallic coatings. The high deposition temperature and complex interaction of the process parameters result in tensile residual stresses in thick metallic layers. Tensile residual stresses are widely known to affect the integrity of metallic coatings. The present study uses a combination of hole drilling and micro-indentation techniques to evaluate the residual stress developed in Ni-based metallic coatings deposited on stainless steel substrate using a direct current plasma spray torch. The metallic coating samples are first characterized by microscopy, surface roughness measurement, micro-indentation, and scratch tests before through-thickness residual strain measurement via the incremental hole-drilling method. The residual stress in the metallic coating layers is evaluated from the incremental strain measurements and micro-indentation curves. The studies show that the residual stress can be reliably predicted using the combination of hole drilling and micro-indentation measurements. It is found that tensile residual stresses are developed across the depth of both NiCrAl and Ni-20Al coatings. The variation of the tensile residual stresses across the depth is nonlinear and almost equibiaxial. The residual stress strongly influences the adhesion strength of the thick metallic coating layers.

Original languageEnglish
Pages (from-to)867-881
Number of pages15
JournalJournal of Materials Research and Technology
StatePublished - Sep 2022

Bibliographical note

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  • Characterization
  • Hole drilling method
  • Micro-indentation
  • Residual stress
  • Thermal spray coatings

ASJC Scopus subject areas

  • Ceramics and Composites
  • Biomaterials
  • Surfaces, Coatings and Films
  • Metals and Alloys


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