The distribution of residual stresses is a crucial factor in governing the performance of thermal-sprayed coatings. Even though this issue has been extensively investigated in previous reports involving homogeneous coatings, little progress has been made when it comes to composite coatings. Here, a novel type of elasto-plastic analytical model is proposed to study the residual stresses in a two-component composite coating prepared through thermal spraying process, in which the quenching stresses and thermal stresses are taken into consideration based on the assumption of layer-by-layer deposition. An arc-sprayed Fe-Al layered composite coating is applied as the model system for the case study. The results show that the distribution of residual stress in the Fe-Al two-component interlaced composite coating is quite different from that of a homogeneous thermal-sprayed coating. As the coating thickness increases, the difference becomes more significant. Benefiting from the improvement in residual stress distribution, it is confirmed by the analytical model and experimental investigation, that the two-component composite structure made of alternate layers of a hard steel and a soft aluminum can be used for forming thick coatings.

残余应力的分布是控制热喷涂涂层性能的关键因素。尽管在之前涉及均匀涂层的报告中已经对这个问题进行了广泛的研究，但在复合涂层方面几乎没有取得任何进展。在这里，提出了一种新型的弹塑性分析模型来研究通过热喷涂工艺制备的双组分复合涂层中的残余应力，其中基于层的假设，考虑了淬火应力和热应力-逐层沉积。电弧喷涂 Fe-Al 层状复合涂层被用作案例研究的模型系统。结果表明，Fe-Al双组分交错复合涂层的残余应力分布与均质热喷涂涂层存在较大差异。随着涂层厚度的增加，差异变得更加显着。受益于残余应力分布的改善，分析模型和实验研究证实，由硬钢和软铝交替层构成的双组分复合结构可用于形成厚涂层。