Cold spray (CS) residual stress was measured by the X-ray diffraction (XRD) and contour methods. The residual stress components SX and SY, perpendicular to the thickness, have similar distributions and approximately equal magnitudes. Both are compressive on the deposited surface and become tensile inside the structure. An advanced simulation model based on the arbitrary Lagrangian–Eulerian (ALE) method was developed to investigate the residual stress distributions in a single CS microparticle and multi-layer CS microparticles and reveal the formation mechanism. The residual stress components SX and SY predicted by the proposed simulation model have the same distribution as shown by the measurements, i.e., compressive on the surface and tensile inside. As the number of deposition layers increases, the position of maximum tensile stress moves from the substrate to the deposited layers. The residual stress component SZ in the direction of the deposition thickness shows alternate tensile and compressive distributions in the transverse direction, which is quite different from that of the transverse component. The formation of CS residual stress is mainly affected by three aspects: the collisions among microparticles, the interactions between microparticles in the same layer, and interactions between microparticles in different layers. The present work provides a guideline for effectively tailoring the residual stress in CS parts and thereby improving the fatigue lifetime.

通过X射线衍射（XRD）和轮廓法测量冷喷涂（CS）残余应力。垂直于厚度的残余应力分量SX和SY具有相似的分布和近似相等的大小。两者在沉积的表面上都是压缩性的，并在结构内部变得拉伸。建立了基于任意拉格朗日-欧拉（ALE）方法的高级仿真模型，以研究单个CS微粒和多层CS微粒中的残余应力分布，并揭示其形成机理。所提出的仿真模型预测的残余应力分量SX和SY具有与测量结果相同的分布，即在表面上受压并在内部受拉。随着沉积层数的增加，最大拉伸应力的位置从基材移至沉积层。沿沉积厚度方向的残余应力分量SZ在横向方向上显示出交替的拉伸和压缩分布，这与横向分量完全不同。CS残余应力的形成主要受三个方面的影响：微粒之间的碰撞，同一层中微粒之间的相互作用以及不同层中微粒之间的相互作用。本工作为有效调整CS零件中的残余应力，从而提高疲劳寿命提供了指导。沿沉积厚度方向的残余应力分量SZ在横向方向上显示出交替的拉伸和压缩分布，这与横向分量完全不同。CS残余应力的形成主要受三个方面的影响：微粒之间的碰撞，同一层中微粒之间的相互作用以及不同层中微粒之间的相互作用。本工作为有效调整CS零件中的残余应力，从而提高疲劳寿命提供了指导。沿沉积厚度方向的残余应力分量SZ在横向方向上显示出交替的拉伸和压缩分布，这与横向分量完全不同。CS残余应力的形成主要受三个方面的影响：微粒之间的碰撞，同一层中微粒之间的相互作用以及不同层中微粒之间的相互作用。本工作为有效调整CS零件中的残余应力，从而提高疲劳寿命提供了指导。以及不同层中微粒之间的相互作用。本工作为有效调整CS零件中的残余应力，从而提高疲劳寿命提供了指导。以及不同层中微粒之间的相互作用。本工作为有效调整CS零件中的残余应力，从而提高疲劳寿命提供了指导。