Abstract
The wire-arc spraying process, one of several thermal spray processes, has gained a sizable part of the thermal spray market. However, better control is needed for this process to be used for applications of high precision coatings. This study is aimed at investigating the liquid-metal droplet formation process in order to identify methods for droplet trajectory control. A high speed Kodak imaging system has been used to observe the droplet formation for different operating conditions. Decreasing the upstream pressure and the current levels leads to a reduction in the asymmetric melting of both the anode and cathode. By decreasing the interactions of the large eddy structures with the formed metal agglomerates, one can achieve better control of the particle trajectories and jet divergence. Thus, coatings can be obtained with higher definition and improved reliability.
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Hussary, N.A., Heberlein, J.V.R. Atomization and particle-jet interactions in the wire-arc spraying process. J Therm Spray Tech 10, 604–610 (2001). https://doi.org/10.1361/105996301770349123
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DOI: https://doi.org/10.1361/105996301770349123