Frequency dependence of sound field effect on microstructure and wear performance of plasma sprayed Ni-10 wt.%Al coatings

Abstract

In this work, we applied sound fields with various frequencies to the plasma spraying process of Ni-10 wt.%Al alloy coatings. The effects of the sound field frequency on the microstructure, residual stress, and wear performance of the coatings were investigated. A lamellar structure was formed in the coatings sprayed with and without sound field. Both the compactness and cohesion of the coatings were enhanced by increasing the sound field frequency. Residual stress of the coatings decreased following the order of sound field frequency: 0 Hz, 100 Hz, 500 Hz, and 300 Hz. Adhesive wear was the main wear model of the coatings sprayed with and without sound field. Friction coefficient and wear rate of the sprayed coatings were both decreased with increasing sound field frequency. Enhancements of the microstructure transformation, residual stress reduction, and wear performance were all attributed to the effects of the sound field during the plasma spraying process.