Abstract
The relationship between roughness caused by blasting and adhesion of spray coatings on aluminum container substrates was studied through various experiments as part of measures for improving the adhesion of the 75mass%Cr-Fe alloy plasma spray coating for sulfi dation corrosion resistance, which is applied on the inner surface of cylindrical Al containers of high-temperature type NAS batteries. Surface roughness of μmRa2.8 - 7.3 was acquired by using Al2O3 particle size #100 (212 - 75μm) to #46 (600 - 250μm) grit. In order to achieve uniform roughness and a clean surface, a combination of blasting when the nozzle was being inserted from the top of the container, and air blowing when the nozzle was being removed was done. It was determined that when Al2O3 particles of size #100 grit was used, a good anchoring shape was formed throughout with a roughened surface of μmRa 2.8. When the internal surface of 3000 Al cylindrical containers were continually blasted using particle size #100 grit, the initial surface roughness of μmRa3.7 - 3.9 only deteriorated to about μmRa2.6. A 75mass%Cr-Fe alloy spray coating was applied to the Al cylindrical containers that were roughened using particle size #100 grit. This coating showed cracks by a bending test, but no peeling occurred. This coating was examined by a tensile strength test and showed good adhesion at 64 - 66 MPa. Through experiments, it was proven that spray coatings formed on the Al cylindrical containers after receiving optimal blasting with particle size #100 grit had good adhesion and corrosion resistance after being used for NAS batteries that stored electrical power for about nine years.
