Abstract

The aim of this work is to evaluate the residual stresses in advanced composite ceramic coatings (60wt% Al₂O₃ – 40wt% SiO₂) was produced by thermal spraying coating (flame spraying) on the mild steel substrate (AISI 1050) steel. The bond coat used in this work was AlNi alloy between metallic substrate and advanced composite ceramic coatings which was implemented by flame spraying technique. The thickness of bond coating was (150ϻm) and for composite ceramic coating was (450 ϻm). the residual stresses evaluated by X-Ray diffraction technique were compressive residual stresses ( -62.6099), while by finite element method were compressive residual stresses (-68.491). The percentage of agreement between the residual stresses evaluated by X-Ray diffraction technique and finite element technique was (91.509%).