The residual stress state in cold spray coatings, which is typically compressive in nature, can be crucial for the coating integrity at high levels or for thick coatings. As an alternative, the analysis using the curvature measurement was applied in this study. The stress measurement during cold spray deposition was made by using an in situ coating property sensor (ICP sensor), which is relatively widely used in thermal spray and enables a fast comparison of several process parameters. The results were then compared to post-deposition curvature measurements. It could be revealed that the usage of a very slow robot traverse speed can lead to tensile residual stresses in cold-sprayed coatings. This finding was explained by the high local temperature during deposition and the formation of tensile stresses during cooling of the deposited material to the average substrate temperature. The increase in the powder feed rate can increase this effect. Preheating did not influence the final stress state. An analytical model is presented which can at least semi-quantitatively explain the observed findings. As an outcome of the research work, it is now possible to adjust the residual stress state in cold spray coatings from tensile to compressive and vice versa with the opportunity of a zero stress state.

冷喷涂涂层中的残余应力状态（本质上通常是压缩应力）对于高水平或厚涂层的涂层完整性至关重要。作为替代方案，本研究应用了使用曲率测量的分析。冷喷涂沉积过程中的应力测量是通过使用原位涂层特性传感器（ICP传感器）进行的，该传感器在热喷涂中应用相对广泛，可以快速比较多个工艺参数。然后将结果与沉积后曲率测量结果进行比较。可以看出，使用非常慢的机器人移动速度会导致冷喷涂涂层中产生拉伸残余应力。这一发现可以通过沉积期间的局部高温以及沉积材料冷却到平均基板温度期间形成的拉伸应力来解释。增加送粉速度可以增强这种效果。预热不影响最终应力状态。提出了一个分析模型，它至少可以半定量地解释观察到的结果。作为研究工作的成果，现在可以通过零应力状态的机会将冷喷涂涂层中的残余应力状态从拉伸调整为压缩，反之亦然。