The mechanism of adhesion of the plasma jet-sprayed Ni, Cr, Mo, Ta and W coatings to the Al and mild steel substrates is in vestigated. The compositions of the boundary layer between the coating and the substrate are made clear by application of the X-ray diffraction analysis.
Moreover, in order to appreciate in detail the adhesive mechanism and the composition of the boundary layer, an experiment on the behavior of bonding between the substrate and Ni drop heated by the levitation melting process is also carried out.
Main results of the experiment are summarized as follows:
(1) The substrate surface is melted by the spraying particles, and a boundary layer is formed between the coating and the substrate.
(2) The layer consists of an intermetallic compound formed by each element of the coating and the substrate.
(3) The layer is important for the sprayed coating to improve the adhesion to the substrate.
(4) The mechanism of adhesion of the sprayed coating deposited to the substrate surface and the composition of the boundary layer are made clear from the results of the experiment by the levitation melting process.