Cohesive strength of plasma sprayed Ni-10wt.%Al coatings enhanced by ultrasonic and depended on the power density

Plasma spray is a promising technology for surface protection and modification in many industrial application fields. However, the low adhesive or cohesive strength of the plasma sprayed coatings limited their further application. The cohesive strength was enhanced 115% ultra-sonicating the substrate during the plasma spraying process of Ni-10wt.%Al coatings. With the increase of power density from 0 to 1.32 W/cm2, the porosity, residual stress and strain were all decreased. However, when the power was further increased to 2.20 W/cm2, the porosity, residual stress and strain were all increased. Ultrasonic energy and the ultrasonic effects of acoustic pressure, acoustic streaming, heat effect, and cavitation effect would affect the physical processes of wetting, filling and solidification of the molten droplets during the plasma spraying process, affecting the microstructure and cohesive strength of the plasma sprayed coatings. The ultrasonic energy and ultrasonic effects which are affected by the ultrasonic power density affecting the fundamental physical processes is the key to enhance the cohesive strength of the plasma sprayed coatings.