Abstract
The particle size distribution of the spray material is recognized as an important parameter in plasma spraying, although it is still a subject of controversy. However, it stands to reason that all the particles impinging on the substrate must be in a molten state. Overheating of small particles leads to vaporization and loss in efficiency. Inadequately heated coarse particles result also in reduced efficiency and in poor quality coatings. Titanium carbide is a material of considerable interest, mostly in the hard surfacing industry and for high thermal flux protection. For TiC coatings prepared by plasma spraying, attempts have been made to produce dense coatings. Previous studies on gaseous environments and spraying parameters always resulted in porous deposits. This study assesses the influence of the particle size distribution on deposition efficiency and coating density. Commercial TiC powders were classified in different fractions and sprayed under selected spraying conditions. The results indicate that both the size and particle size distribution of powders play a decisive role with respect to deposition efficiency and coating density.
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