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Influence of spray pattern on residual stresses and coating properties of arc-sprayed aluminum bronzes sprayed with different gas mixtures

: Hauer, M.; Banaschik, R.; Kroemmer, W.; Henkel, K.-M.

Azarmi, F. ; The Thermal Spray Society -TSS-; ASM International; Deutscher Verband für Schweißen und Verwandte Verfahren e.V. -DVS-; International Institute of Welding -IIW-:
ITSC 2018, International Thermal Spray Conference and Exposition. Conference proceedings : Orlando, Florida, 07-10 May 2018; USB-Stick
Materials Park, Ohio: ASM International, 2018
ISBN: 978-1-62708-160-3
International Thermal Spray Conference and Exposition (ITSC) <2018, Orlando/Fla.>
Fraunhofer IGP ()

Previous own works showed the negative effects of air as pressurizing gas regarding the cavitation erosion resistance of arc-sprayed aluminum bronze coatings due to oxidation and tensile residual stresses. Furthermore, coatings sprayed with a mixture of nitrogen and hydrogen revealed superior coating qualities. A meander-shaped spray pattern was used in the aforementioned studies.
However, other publications reveal, that a spiral-shaped spray pattern positively influences heat transfer during the spray process and thus also coating properties. Hence, the alloys CuAl9Ni5Fe4Mn and CuMn13Al8Fe3Ni2 were arc-sprayed with a spiral-shaped pattern in this work, using both pressurized air and a mixture of nitrogen and hydrogen.
Process temperatures were recorded by thermographic imaging and residual stresses were measured by modified hole-drilling method using ESPI. Moreover, analyses of the cavitation erosion behavior and other properties were carried out. The results of this study are compared to the corresponding previous works with a meander-shaped spray pattern.