Abstract
Twin wire arc sprayed aluminum coatings are used extensively in semiconductor processing equipment. In certain applications, such as metal reclamation, rough coating textures are desirable as the added surface area facilitates the collection of metals and lowers manufacturing costs. There are many factors that affect the surface roughness of twin wire arc sprayed coatings. This study investigates coating conditions that produce rough textures and the influence of surface roughness on bond strength. Traditional theory of arc spraying has been that to obtain a rough coating, particle velocity should be reduced by decreasing the atomizing air pressure of the system. Decreasing air pressure, however, may have a negative impact on bond strength, the extent of which is assessed in this study.
