Gordon England Surface Engineering Forum

Thermal Spray Coating Metallography
Effect of Process and Powder Size

Metallography: Combustion or Flame Spray Coating produced using Coarse Nickel Chromium Powder
Combustion Spray Coarse 80/20 NiCr
Powder
Metallography: Combustion or Flame Spray Coating produced using Fine Nickel Chromium Powder
Combustion Spray Fine 80/20 NiCr
Powder
Metallography: Plasma Spray Coating produced using Coarse Nickel Chromium Powder
Plasma Spray Coarse 80/20 NiCr
Powder
Metallography: Plasma Spray Coating produced using Fine Nickel Chromium Powder
Plasma Spray Fine 80/20 NiCr
Powder

The photomicrographs above show fairly typical differences in microstructure of coatings produced by plasma spray and combustion powder spray processes and the effect of changing powder particle size.

Plasma sprayed coatings generally have finer, denser microstructures with less oxide inclusions than combustion powder sprayed coatings. Plasma provides rapid heating, low particle flight time, more inert flame and higher velocity than combustion flame.

Generally, coarse powders produce a coarser and more open structured coatings with less oxidation than fine powders. This is mainly due to the differences in surface area of the powder particles exposed in the flame.







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