Variation of splat shape with processing conditions in plasma sprayed alumina coatings

This paper is on various splat shapes obtained using three alumina based powders sprayed on various substrates. The parameters considered were substrate preheating temperature, nozzle diameter, and secondary and primary gas flow rates. The splat shape was found to be strongly dependent on spraying conditions. The substrate preheating temperature determined the degree of substrate wetting by the splat. A change in either nozzle diameter or primary gas flow rate brought about a change in the particle momentum and subsequently, a change in splat shape. The splat shape differed widely on an as – sprayed bond coat as compared to a polished one, owing to splat confinement by surface asperities. Sub-microscale surface roughness of polished substrate surfaces showed an increase with the preheating temperature and this in turn, resulted in better substrate wetting by the splats.