Abstract
Wire arc spraying is a coating process in which minor modifications of the configuration and spray parameters can have a strong impact on coating characteristics. A study on the effects of the fluid dynamics of the atomizing gas on the coating properties is presented. Different types of nozzles, shrouds, and gases have been used to provide various flow velocities and reactive environments in the metal atomization region. The effects on particle velocity, coating density, composition, and interface characteristics between the coating and the substrate have been evaluated. It is clear that higher gas velocities improve practically all coating properties, but also increase oxide content in the coating. However, the oxidation can be drastically reduced if nonoxidizing gases are used for atomization in combination with a shroud. A discussion on the physical effects contributing to the observed adhesion improvements and interfacial properties is provided.
Similar content being viewed by others
References
Thermal Spraying: Practice, Theory and Applications, Committee on Thermal Spraying, American Welding Society, Miami, FL, 1985, p 3–12
H.-D. Steffens, Z. Babiak, and M. Wewel, Recent Developments in Arc Spraying, IEEE Trans. Plasma Sci., Vol 18 (No. 6), 1989, p 974
M.L. Thorpe, Thermal Spray Applications Grow, Adv. Mater. Process., Vol 134 (No. 4), 1988, p 69
H.-D. Steffens, Metallurgical Changes in the Arc Spraying of Steel, Br. Weld. J., Vol 13 (No. 10), 1966, p 597–605
R.W. Fox, Introduction to Fluid Mechanics, John Wiley & Sons, 1973, p 54
S.G. Russ, “Turbulence and Entrainment in Plasma and Heated Jets,” Ph.D. thesis, University of Minnesota, 1993
David R. Marantz and Daniel R. Marantz, State of the Art Arc Spray Technology, Thermal Spray Research and Applications, T.F. Bernecki, Ed., ASM International, 1990, p 113
K.S. Fessenden and Z. Zurecki, Sliding Wear Resistance of Electric Arc Sprayed Coatings, Thermal Spray Research and Applications, T.F. Bernecki, Ed., ASM International, 1990, p 81
X. Wang, D. Zhuang, E. Pfender, J. Heberlein, and W. Gerberich, Effect of Atomizing Gas Pressure on Coating Properties in Wire Arc Spraying, Thermal Spray Industrial Applications, C.C. Berndt and S. Sampath, Ed., ASM International, 1994, p 587–592
T. Watanabe, X. Wang, J. Heberlein, E. Pfender, and W. Herwig, Voltage and Current Fluctuations in Wire Arc Spraying as Indications for Coating Properties, Thermal Spray: Practical Solutions for Engineering Problems, C.C. Berndt, Ed., ASM International, 1996, p 577–583
E. Pfender, Plasma Jet Behavior and Modeling Associated with the Plasma Spray Process, Thin Solid Films. Vol 238, 1994, p 228–241
X. Wang, S. Russ, J. Heberlein, W. Gerberich, and E. Pfender, Arc Spray by a Supersonic Atomizing Gas Stream, Proceedings of the 11th International Symposium on Plasma Chemistry (Leicestershire, England), J. Harry, Ed., Vol 1, 1993, p 133
A.W. Schrader, Modern Approaches to Wettability, Theory and Applications, Plenum Press, 1992, p41–45
X. Wang, J. Heberlein, E. Pfender, and W. Gerberich, Effect of Shrouded CO2 Gas Atomization on Coating Properties in Wire Arc Spray, Thermal Spray Science and Technology Proceedings, C.C. Berndt and S. Sampath. Ed., ASM International, 1995, p 31–37
N. Birks and G. Meier, Introduction to High Temperature Oxidation of Metals, Edward Arnold Ltd., London, 1983, p 67
H. Herman, Plasma Sprayed Coatings, Sci. Am., Vol 45 (No. 7), 1988, p 112–117
C.C. Berndt, Instrumental Tensile Adhesion Tests on Plasma Sprayed Barrier Coatings, J. Mater. Eng., Vol 11 (No. 4), 1989, p 275
H.-D. Steffens, D. Wielage, and J. Drozak, Interface Phenomena and Bonding Mechanism of Thermally Sprayed Metal and Ceramic Composites, Surf. Coat. Technol., Vol 45 (No. 3), 1991, p 299
C.C. Berndt, The Need for Standardization of Testing Techniques in Thermal Spray Industry, Thermal Spray Research and Applications, T. Bernecki, Ed., ASM International, 1990, p 325
C.C. Berndt and R. McPherson, Adhesion of Plasma Sprayed Ceramic Coatings to Metals, Mater. Sci. Res., Vol 14 (No. 3), 1983, p 619
F.S. Shieu, R. Raj, and S.L. Sass, Control of the Mechanical Properties of Metal-Ceramic Interfaces through Interfacial Reactions, Acta Metall. Mater., Vol 38 (No. 11), 1990, p 2215
R. Raj, A. Pearce, and C.M. Kennefick, Thin Films of Transition Metals on Oxides, Acta Metall. Mater., Vol 38 (No. 11), 1990, p 2215
Author information
Authors and Affiliations
Rights and permissions
About this article
Cite this article
Wang, X., Heberlein, J., Pfender, E. et al. Effect of nozzle configuration, gas pressure, and gas type on coating properties in wire arc spray. J Therm Spray Tech 8, 565–575 (1999). https://doi.org/10.1361/105996399770350269
Received:
Revised:
Issue Date:
DOI: https://doi.org/10.1361/105996399770350269