Development of High Density Twin Wire Arc Sprayed Coatings on Metallic Foam Substrates

In this study, twin wire arc spraying is used to deposit dense Inconel skins on 40 PPI nickel foam sheets. A design-of-experiments approach is used to investigate the effects of grit blasting on the surface characteristics of paste-filled foam. In-flight behavior of molten droplets and its effect on coating properties is assessed at three spray distances. The Inconel coatings are evaluated based on SEM and EDS analysis, roughness measurements, and adhesion testing. The results indicate that acceptable adhesion, porosity, and oxide content can be achieved over a small range of grit blasting parameters.