Cohesive strength of plasma sprayed Ni-10wt.%Al coatings enhanced by ultrasonic and depended on the power density

Plasma spray is a promising technology for surface protection and modification in many industrial application fields. However, the low adhesive or cohesive strength of the plasma sprayed coatings limited their further application. The cohesive strength was enhanced 115% ultra-sonicating the substrat...

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Bibliographic Details
Published in:Applied physics. A, Materials science & processing Materials science & processing, 2024-09, Vol.130 (9), Article 627
Main Authors: Liu, Huiqiang, Wang, Haibo, Wang, Jichun, Gao, Pengfei, Han, Guofeng, Wang, Xiaoming, Yang, Baijun
Format: Article
Language:English
Subjects:
Acoustic streaming
Adhesive strength
Aluminum coatings
Cavitation
Characterization and Evaluation of Materials
Cohesion
Condensed Matter Physics
High temperature effects
Industrial applications
Machines
Manufacturing
Nanotechnology
Nickel
Optical and Electronic Materials
Physics
Physics and Astronomy
Plasma
Plasma spraying
Porosity
Pressure effects
Processes
Rapid Communications
Residual energy
Residual stress
Solidification
Sprayed coatings
Strain
Substrates
Surfaces and Interfaces
Thin Films
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Summary:Plasma spray is a promising technology for surface protection and modification in many industrial application fields. However, the low adhesive or cohesive strength of the plasma sprayed coatings limited their further application. The cohesive strength was enhanced 115% ultra-sonicating the substrate during the plasma spraying process of Ni-10wt.%Al coatings. With the increase of power density from 0 to 1.32 W/cm2, the porosity, residual stress and strain were all decreased. However, when the power was further increased to 2.20 W/cm2, the porosity, residual stress and strain were all increased. Ultrasonic energy and the ultrasonic effects of acoustic pressure, acoustic streaming, heat effect, and cavitation effect would affect the physical processes of wetting, filling and solidification of the molten droplets during the plasma spraying process, affecting the microstructure and cohesive strength of the plasma sprayed coatings. The ultrasonic energy and ultrasonic effects which are affected by the ultrasonic power density affecting the fundamental physical processes is the key to enhance the cohesive strength of the plasma sprayed coatings.
ISSN:0947-8396
1432-0630
DOI:10.1007/s00339-024-07793-0