Considering the material nonlinearity features

the temperature field

stress field and displacement field of plasma cladding Q235 steel were simulated by thermo-mechanical coupling based on ABAQUS finite element method of life and death and Goldak heat source model.The real residual stress was measured by blind hole method.The results reveal that the Goldak model can simulate the plasma heat source well and the simulated results are stable

which is consistent with the actual cladding testing.In Xand Zpaths

the calculated value of residual stress is consistent with the variation trend of measured one.The maximum difference between the measured value and simulated one of longitudinal residual stress along X path is 43 MPa

and the average value is 6.2 MPa.There exists some deviation along the Z path

however

the overall trend tends to be consistent.The average simulated value of longitudinal residual stress is-189.54 MPa

while the average measured value is-211.5 MPa.After completion of cladding

the maximum deformation is 0.05 mm

which appears in the center of cladding layer

and the deformation of Q235 steel matrix is less than 0.01 mm.