The super-elasticity behavior of a NiTi-shape memory alloy (SMA) is very promising regarding cavitation resistance. The need of high vacuum conditions by thermal spraying processes, to avoid oxidation, has always been and still is the main obstacle for the widespread of NiTi as a coating material. This work deals with studying the effect of the different shroud concepts on the obtained oxide content and the phases of the obtained twin wire arc sprayed (TWAS) coatings. The concepts include the use of argon as a shield in gas shroud (GS) as well as the use of an extended air cap attachment as a massive shroud (MS). The use of MS-concept led to a significant decrease in oxide content and therefore was selected to spray pre-alloyed NiTi-SMA wires. The standoff distance between the MS-outlet and the substrate surface shows also an effect on the obtained phases and thus on the behavior of the obtained coatings. At lower standoff distance a pseudo-elastic behavior was obtained and therefore a higher cavitation and wear resistance. The use of argon as atomization and shield gas with a massive shroud could be a cost-effective alternative for vacuum process in case of spraying NiTi-SMA pre-alloyed feedstock materials.

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