ISIS Neutron and Muon Source Data Journal

Residual Strain Measurement in Multi-Phase Cold Spray Coatings

Abstract: Cold spray (CS) is increasingly used to deposit multi-phase and composite coatings for aerospace, energy, and repair applications. These coatings derive their performance from the synergistic combination of ductile metallic matrices and hard ceramic reinforcements. However, the severe plastic deformation during cold spray generates complex residual stress fields whose distribution between matrix and reinforcement phases is unknown. Most residual strain (or stress) studies to date on CS coatings focus on single-phase coatings. We propose to use time-of-flight (TOF) neutron diffraction on ENGIN-X to map phase-specific residual strains through the thickness of CS composites. The unique ability of ENGIN-X to resolve diffraction peaks from multiple phases (ductile metallic matrix and the hard/brittle reinforcement phase) will allow non-destructive quantification of strains in coating-substrate system. These results will provide the first direct experimental evidence of strain sharing in CS composites, enabling validation of micromechanical models and guiding process optimisation for durability and adhesion. A 400 m thick cold sprayed WC-CoCr + Ni coatings, developed onto a steel disc substrate (5 mm thick and 10 mm diameter) with fine polished surface, and coarse grit blasted surface.

Principal Investigator: Professor Nadimul Faisal
Experimenter: Dr Anil Prathuru
Experimenter: Dr Calum Hicks
Experimenter: Dr Tiziana Marrocco
Local Contact: Dr Joe Kelleher
Experimenter: Mr Caleb Griffin

DOI: 10.5286/ISIS.E.RB2610061

ISIS Experiment Number: RB2610061

Publisher: STFC ISIS Neutron and Muon Source

Data format: RAW/Nexus
Select the data format above to find out more about it.

Data Citation

The recommended format for citing this dataset in a research publication is as:
[author], [date], [title], [publisher], [doi]

For Example:
Professor Nadimul Faisal et al; (2026): Residual Strain Measurement in Multi-Phase Cold Spray Coatings, STFC ISIS Neutron and Muon Source, https://doi.org/10.5286/ISIS.E.RB2610061

Data is released under the CC-BY-4.0 license.