Abstract
In the present study, microstructural analysis was carried out to investigate the effect of substrate surface chemistry on splat formation. Ni powder was sprayed onto stainless steel substrates exhibiting two different surface conditions (polished and oxidized) by high-velocity oxy-fuel (HVOF) thermal spray. X-ray photoelectron spectroscopy (XPS) was employed to investigate the chemical state of the surfaces which indicated the presence of the adsorbates on the oxidized substrate. Single splats of different morphologies from both samples were examined using a range of characterization techniques including scanning electron microscopy (SEM), focused ion beam (FIB) microscopy and transmission electron microscopy (TEM) and energy-dispersive x-ray spectroscopy (EDS) interfaced to both SEM and TEM. This provided information on the particle solidification behavior and splat formation mechanism following impact on substrates with distinct surface conditions. The results showed the effect of oxidized surface adsorbates on splat morphology, pore formation and splat–substrate interactions. These microstructural findings, aided by theoretical models, revealed that a mixture of mechanical and metallurgical bonds exists between the splats and both substrates.
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Acknowledgment
The authors would like to acknowledge the financial support from UNSW for an University International Postgraduate Award (UIPA). The authors also acknowledge the technical support provided by Dr. Bill Gong of SSEAU, UNSW, along with Sean Lim, Yin Yao and the other staff at the EMU, UNSW for their help in the experiments described in this study.
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Abbas, M., Smith, G.M. & Munroe, P.R. Microstructural Characterization of HVOF-Sprayed Ni on Polished and Oxidized Stainless Steel Substrates. J Therm Spray Tech 29, 1093–1110 (2020). https://doi.org/10.1007/s11666-020-01031-8
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DOI: https://doi.org/10.1007/s11666-020-01031-8