Thermal spray is a flexible technique enabling deposition of wide choice of feedstock materials including ceramics, metals or the mixture of both. Various spray technologies are available, such as different types of thermal plasma methods, electric arc based methods, HVOF and other combustion methods. Obviously, the fatigue properties of coated bodies will differ based on the choice of feedstock material and on the spray technology used. Comparison was made of fatigue properties of bodies with Alumina, Ni-5wt%Al and composite coatings produced by gas and water stabilized plasma spray. It has been found, for instance, that Alumina coatings sprayed by water stabilized plasma torch (WSP) had substantially increased fatigue life times of specimens compared to specimens with coatings of the same feedstock deposited by the gas stabilized plasma torch. Measured fatigue data were related to a detailed structural characterization of the tested coatings. Obtained results are discussed with regard to our previous results obtained during fatigue tests of specimens with one-component coatings.

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