Thermally sprayed coatings are inherently associated with residual stresses in the coatings. These stresses vary in nature and magnitude, and have a pronounced effect on the physical and mechanical properties of coatings. The high speed hole drilling method is widely used to measure the residual stress. Due to the nature of the thermally sprayed coatings, its application for WC/Co coatings is limited. In the current study, WC-12Co coatings were deposited by HVOF. Morphological studies were conducted using optical microscopy, scanning electron microscopy (SEM) and X-ray diffraction (XRD), respectively to evaluate the powder and coating characteristics. The Electro discharge drilling method was developed to measure the residual stress in WC-Co thermally sprayed coatings. The experimental results reveal that the stress curves are not uniform through the coating thickness. It has been found that the mean residual von Misses stress is of approximately 222MPa. Obtained results are in good agreement with the results measured from XRD patterns and reported values from literatures. The developed method confirms the feasibility of residual stresses measurement for HVOF thermally sprayed WC-Co coatings.

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