An experimental study was conducted to study the effect of impact velocity and substrate temperature on splat morphology using a wire arc spraying system. Aluminum was sprayed onto polished AISI304L substrates held at various temperatures. In-flight particle parameters (size, velocity, temperature) were measured using a DPV 2000 system. Individual splats deposited on the substrate were photographed. Comparisons between the in-flight particle size distribution and the final splat size distribution showed that increasing substrate temperature results in increased mean spread factor. A transition temperature from splash to disk splats was determined. Coatings were also produced at various substrate temperatures and porosity levels measured. The effect of substrate temperature on deposition efficiency and coating adhesion was measured. Increasing substrate temperature was found to improve both deposition efficiency and adhesion strength.

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