Abstract
In this study, the mechanisms of splat formation and the influence of substrate surface conditions were studied for NiCr splats HVOF sprayed onto Al. The specimens, having undergone various substrate pre-treatments, were observed at high resolution using various electron microscopy techniques with emphasis on the splat microstructure and the splat-substrate interface. From the observations made here, a model for splat formation is proposed, whilst the effects of surface chemistry on this process were investigated. It was found that that due to the deformation of the substrate on impact of the partially molten particle, effective contact may be achieved between the substrate and the splat. However, in many cases, much of the initial projected particle did not adhere to the substrate after impact. The presence of oxide or hydroxide layers on the surface of the substrate was influential on the adhesion of the NiCr splat
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