This paper extensively studies the effects of discharging condition on properties of sprayed coating by wire explosion. Charging energy and condenser capacity are ranged from 185J to 415J and 144μF to 280μF, respectively; small condensor capacity corresponds to large circuit frequency. Large charging energy as well as small condensor capacity result in small size and larger velocity of flying particles. It is shown that the particle size distribution is mainly dominated by charging energy. Flying particles with small diameter and large velocity give fine sprayed coating surface. The optimal combination of size distribution and velocity of flying particles, however, is necessary to increase mass of deposits and to obtain strong adhesion strength with the substrate. It is found that adhesion strength between substrate and sprayed coating is mainly dominated by mechanical bonding, i.e., anchoring effect.
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