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Measuring residual strain and stress in thermal spray coatings using neutron diffractometers.

Faisal, N.H.; Ahmed, R.; Prathuru, A.K.; Paradowska, A.; Lee, T.L.


R. Ahmed

A. Paradowska

T.L. Lee


Background: During thermal spray coating, residual strain is formed within the coating and substrates due to thermo-mechanical processes and microstructural phase changes. Objective: This paper provides a comprehensive guide to researchers planning to use neutron diffraction technique for thermal spray coatings, and reviews some of these studies. Methods: ENGIN-X at the ISIS spallation source is a neutron diffractometer (time-of-flight) dedicated to materials science and engineering with high resolution testing. The focus is on the procedure of using ENGIN-X diffractometer for thermal spray coatings with a view that it can potentially be translated to other diffractometers. Results: Number of studies involving neutron diffraction analysis in thermal spray coatings remain limited, partly due to limited number of such strain measurement facilities globally, and partly due to difficulty is applying neutron diffraction analysis to measure residual strain in the thermal spray coating microstructure. Conclusions: This technique can provide a non-destructive through-thickness residual strain analysis in thermally sprayed components with a level of detail not normally achievable by other techniques. Neutron sources have been used to measure strains in thermal spray coatings, and here, we present examples where such coatings have been characterised at various neutron sources worldwide, to study residual strains and microstructures.


FAISAL, N.H., AHMED, R., PRATHURU, A.K., PARADOWSKA, A. and LEE, T.L. 2022. Measuring residual strain and stress in thermal spray coatings using neutron diffractometers. Experimental mechanics [online], 62(3), pages 369-392. Available from:

Journal Article Type Article
Acceptance Date Oct 25, 2021
Online Publication Date Nov 10, 2021
Publication Date Mar 31, 2022
Deposit Date Nov 8, 2021
Publicly Available Date Nov 8, 2021
Journal Experimental mechanics
Print ISSN 0014-4851
Electronic ISSN 1741-2765
Publisher Springer
Peer Reviewed Peer Reviewed
Volume 62
Issue 3
Pages 369-392
Keywords Residual strain; Residual stress; Neutron diffraction techniques; Thermal spray coatings; ENGIN-X; Neutron diffractometers
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Additional Information A preprint of this article was posted on Research Square on 12.04.2021. Available from


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