Influence of the spray velocity on arc-sprayed coating structures

Thermal spray processes such as plasma spraying and HVOF have gained markets due to a steady process of development of materials and equipment. One disadvantage of thermal spray processes is that costs must be competitive compared to techniques such as PTA and electroplating. In order to reduce costs, the more economical spray processes like conventional wire flame spraying, as well as arc spraying, are becoming more popular. There are modern arc spray gun designs on the market that meet the requirements of modern coating properties, for example aviation overhaul applications as well as the processing of cored wires. Nevertheless, the physical basis of arc spraying is well known. The aim of the present investigation is to show how the influence of spray velocity (not particle velocity) affects coating structure with respect to arc spray parameters.