The present study investigates the splat formation behaviour of Ni particles plasma sprayed onto AISI 1008 mild steel and 316 austenitic stainless steel substrates to draw a comparative analysis of splat formation on both surfaces. A range of analytical techniques were used to analyse the surface and cross-sectional characteristics of the splats formed on both substrates. Most of the splats observed on both of the substrates were halo type splats driven by Rayleigh–Taylor instabilities. A linear relationship was identified between the size of the central core of the splats and their outer ring of debris, which was distinct for each substrate. The diffusion profile, obtained through STEM-EDS analysis, revealed a higher degree of diffusion across the interface between splat and stainless steel substrate as compared to mild steel, suggesting a better bond efficiency for stainless steel. Cross-sectional observations, together with theoretical calculations, showed evidence of substrate melting as well as the presence of metallurgical bonds for both mild steel and stainless steel substrates.

本研究研究了镍颗粒等离子喷涂到 AISI 1008 低碳钢和 316 奥氏体不锈钢基材上的镀层形成行为，以对两个表面上的镀层形成进行比较分析。一系列分析技术用于分析在两个基板上形成的板条的表面和横截面特征。在两种基板上观察到的大多数斑块都是由瑞利-泰勒不稳定性驱动的晕型斑块。在 splats 的中心核心的大小和它们的外环碎片之间确定了线性关系，这对于每个基板都是不同的。通过 STEM-EDS 分析获得的扩散曲线显示，与低碳钢相比，在 splat 和不锈钢基材之间的界面上的扩散程度更高，表明不锈钢具有更好的粘合效率。横截面观察与理论计算一起显示了基材熔化的证据，以及低碳钢和不锈钢基材都存在冶金结合的证据。