The testing method was used to evaluate the bond strength of high-strength coatings. In this test, symmetrical cuts were cut along the interface of the coating/substrate exactly by wire cutting, then the two sides were adhered and undrawn by tensile force a-long the interface of the coating/substrate. In order to get a precise evaluation of coating/substrate bonding strength, the stress distribution on the coating/substrate interface and the stress concentration of the crack tip were analysed by finite element method. The bonding strength of thermal sprayed layer with various processing parame...