2005 Volume 46 Issue 11 Pages 2473-2477
The self-fluxing alloy was thermal sprayed by using combustion flame spraying (FS) and high energy plasma spraying (HPS) as well as high velocity oxy-fuel spraying (HVOF) processes under different combustion chamber pressures of 0.56, 0.70 and 0.84 MPa. As-sprayed HVOF (0.56 MPa) coating contained a large amount of non-melted particles. Whereas, the as-sprayed HVOF (0.70 MPa) and (0.84 MPa) coatings were composed of melted and non-melted particles similar to the FS and HPS coatings. The compressive residual stress distributed through-thickness in the as-sprayed HVOF (0.56 MPa) coating. On the other hand, the tensile residual stress distributed through-thickness in the HVOF (0.70 MPa) and (0.84 MPa) coatings as well as the FS and HPS coatings. However, the through-thickness residual stress distribution of the HVOF coatings exhibited a low value under 100 MPa in the whole area of coating.