Coating Material Interaction on Metal Substrate by Application of Plasma Spraying

Abstract

In this paper, Fly-ash+quartz+illmenite with weight percentage ratio: 60:20:20, is deposited on mild steel and copper substrates by atmospheric plasma spraying at various operating power level ranging from 11 to 21 kW. The properties of the coating depend on the interaction of coating powder with plasma, operating condition and the process parameters. The coating quality and behavior depends on Coating surface & interface morphology are studied with Scanning Electron Microscope. For Mild Steel the adhesion strength has varied from 3.5MPa to 6.56MPa and for Mild steel a maximum of 6.56MPa at the power level of 21 kW. In plasma spraying, injected powder size must be large enough not to be vaporized, and not small enough to be completely melted. Each droplet is flattened on impact at the substrate surface and solidified, and the coating consists of many layers of the flattened particles.