For thermal sprayed coatings, compactness of their constituent particles is required in many applications, e.g. to obtain impermeable anticorrosion coating in marine use. We investigated key factors to improve compactibility of deposited particles in HVOF sprayed coatings by condition measurements of spray particles. The results revealed that plastic deformability of the sprayed particles as well as their molten fraction was important to obtain the dense VHOF coatings.

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