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Alternative gas mixtures in arc spraying. A chance to improve coating properties and residual stress states

: Hauer, M.; Henkel, K.M.; Krebs, S.; Kroemmer, W.


Journal of thermal spray technology 27 (2018), Nr.1-2, S.106-118
ISSN: 1059-9630
ISSN: 1544-1016
Fraunhofer IGP ()

The highly cavitation erosion-resistant propeller alloys CuAl9Ni5Fe4Mn (Ni-Al-Bronze) and CuMn13Al8Fe3Ni2 (Mn-Al-Bronze) were arc-sprayed using a mixture of nitrogen and 2% of hydrogen as atomizing gas and different traverse speeds. The objective was to identify the influences of the different spraying conditions, such as temperature regime and melting loss, on the resulting residual stress states and coating properties. Residual stresses were measured by the incremental hole-drilling method using ESPI. Temperature measurements were carried out by thermographic imaging. Microstructural, chemical and mechanical analyses were realized to examine adhesive and cohesive properties. Additionally, the cavitation erosion behavior was investigated to analyze cohesive coating properties. The spraying process itself was improved, which was apparent by mainly enhanced deposition efficiency and reduced surface temperatures. The amount of oxides and pores as well as the melting loss of alloying elements were reduced. Moreover, an increased cavitation erosion resistance and thus coating cohesion as well as less residual stresses were identified. The change in atomizing gas diminished the impact of the quenching stresses on the coating properties. In contrast, the adhesive strength, Young’s moduli and partially the hardness were slightly reduced. With regard to materials, Ni-Al-Bronze revealed superior coating properties in comparison with Mn-Al-Bronze.