Thermal Spray Coating Microstructures

Flame spray coarse NiCr
Combustion Spray Coarse 80/20 NiCr Powder
Flame spray fine NiCr
Combustion Spray Fine 80/20 NiCr Powder
Plasma spray coarse NiCr
Plasma Spray Coarse 80/20 NiCr Powder
Plasma spray fine NiCr
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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