Abstract
Thermal spray is one of the most widely used coating techniques to improve wear, surface fatigue or corrosion properties. In the atmospheric plasma spray (APS) process, a powdered material is melted by hydrogen and argon combustion and is propelled at high speed onto the target substrate. The high impact energy of the particles produces a dense and resistant coating layer. Mechanical and surface properties of the obtained coating depend on various spraying parameters, such as gas flow, traverse speed and spraying distance, among others. In this research, the influence of these manufacturing parameters on the thickness, hardness and resistance of the coating obtained from a Ni-Al alloy sprayed onto an aluminum alloy substrate was studied. In order to analyze the effect of these parameters on the coating properties, an extensive experimental program was carried out. A metallographic analysis, hardness and strength measurements were carried out using the small punch test to locally study the mechanical properties of the coating surface. The design of experiments and the response surface methodology facilitate the assessment of the optimal set of spraying parameters.
Highlights
Components manufactured in different industries require an optimum strength-toweight ratio
Due to the temperatureenhanced oxidation [10], coatings are commonly designed as a thermal barrier coating (TBC) for components that are in contact with hot gases [11,12,13]
A type of TBC commonly used in aeronautics and obtained by thermal spraying is the Ni-Al coating
Summary
Components manufactured in different industries require an optimum strength-toweight ratio Some properties, such as fatigue, creep, creep-fatigue, high temperature, corrosion and wear resistance, must be considered depending on their functionality. Landing gear dampers absorb and dissipate landing impact energy and reduce stresses on the fuselage For this reason, many of the components of the landing gear have usually been plated with hard chrome [1,2,3]. Environmental regulations demand the replacement of these hexavalent chromium components due to their harmful effects on health [4] In this context, coatings obtained by thermal spraying are a feasible alternative because, in addition to environmental issues, they improve mechanical performance in comparison with conventional hard chrome coatings, both for wear and corrosion behavior [3,5,6]. Aluminum substrates are used in applications where the weight must be minimum; the low hardness and tribological properties need to be enhanced by different coating techniques
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