Abstract: The coupled Eulerian-Lagrangian model of Ti and Al mixed particles with different particle size impacting 7B04 aluminum alloy substrate during cold spraying was established by using ABAQUS software. The effects of carrier gas pressure （0.8, 1.6, 2.4 MPa）, carrier gas temperature （350, 450, 550 ℃） and spraying distance （10, 15, 20 mm） on residual stress of the deposite layer were studied. The interaction laws of process parameters on residual stress were analyzed by response surface method. The results show that residual compressive stress was formed in the deposite layer under different cold spraying process parameters. With the increase of carrier gas pressure, the maximum residual compressive stress first increased and then decreased, the residual stress distribution tended to be uniform, and the number of pores decreased. With the increase of carrier gas temperature, the maximum residual compressive stress decreased, the residual stress distribution had no obvious change, and the pore size decreased. With the increase of spraying distance, the maximum residual compressive stress first increased and then decreased, and there was no obvious change in residual stress distribution and pore quantity and size. The carrier gas temperature had the most significant effect on the maximum residual compressive stress, followed by carrier gas pressure, and the spraying distance had the least influence. The interaction effect of carrier gas temperature and carrier gas pressure on the maximum residual compressive stress was the most significant, followed by the interaction effect of carrier gas temperature and spraying distance, and the interaction effect of carrier gas pressure and spraying distance was the least.