Abstract: Two different spraying powders [81FVNS and 80% (443)+20% (105)] were plasma sprayed on two types of substrates (AISI 316 and Ti) in order to verify the effect of differential thermal expansion coefficient (DTEC) between coating and substrate on the final residual stresses generated in the coating. Modulus of elasticity (E) was evaluated for the substrates and coatings (as a composite beam). Free-standing coatings were used to measure the thermal expansion coefficient, as a function of temperature, of the actual coatings with all defects, impurities and typical lamella structure. The results show that the residual stresses seems to be less dependent on the linear thermal expansion coefficients mismatching between substrate and coating, reflecting the importance of the other sources of stresses. i.e. quenching or deposition stresses induced during spraying. The suitable heat treatment condition of the coated samples may release some or most of the residual stresses. However in some cases the sign of the stress was completely changed as a result of neglecting the quenching stresses.

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