Abstract
Analytical formulae are obtained describing the pressure distribution in a flattening droplet along the droplet-substrate interface during thermal spraying at off-normal angles. The magnitudes of droplet-substrate microadhesion, deformation of the substrate surface and the coating porosity depend upon the spraying angle. The theoretical results for % relative porosity are in reasonable agreement with experimental observations at off-normal angles between 30 ° and 90 °.
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