Abstract
The effect of spray angle on the properties of plasma spray deposits has been investigated. Two different materials, NiAl and Cr 3C 2–NiCr, were sprayed at angles from 50 to 90° with respect to the substrate. The spray angle influenced the microstructure and the properties of the deposits. The porosity increased as the spray angle decreased, i.e. as the angle was shifted away from the perpendicular position. The surface roughness of the Cr 3C 2–NiCr deposit was not sensitive to the spray angle, whereas NiAl exhibited an increase as the spray angle decreased. Microhardness, tensile adhesion strength, and interfacial fracture toughness decreased with spray angle. The change of these properties with spray angle is attributed to (1) the morphology of the splats, (2) the change of the local spray angle, and (3) the change of momentum of particles impacting on the substrate or previously deposited particles. The mechanical-property variations arise from porosity changes which occur from the spray angle variations.
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