Residual stresses in spray-formed A2 tool steel

The objective of this work was to investigate the fundamental factors that govern the formation and magnitude of residual stresses in A2 tool steel fa bricated using spray-forming techniques. To that effect, a finite-element m ethod (FEM) was performed by using a commercial code, ABAQUS, to solve for the temperature and displacement fields. Moreover, the residual stresses in the spray-formed materials were measured using x-ray diffraction to compar e the FEM results with experimentation. Two types of substrate material, co pper and Rescor(TM) 780 cer-cast ceramic, were used to investigate the infl uence of heat conduction on residual stress in the preforms. Relatively goo d agreement was found between experimentation and theory. The results show that the residual stress varies greatly with the position in deposited pref orm and that heat-transfer coefficient at the interface of spray-formed mat erial/substrate affects the distribution and magnitude of the residual stre sses significantly.