The aim of this study is to produce free-standing functionally-graded structures in which density varies continuously from 2.2 to 17.3 g/cm3 through a total thickness of 4.5 mm. In order to optimize material performance, it is necessary to account for the different combinations or ratios of materials (i.e., tungsten and aluminum) in the plasma jet when determining mixture laws. A relationship based on the deposition efficiency, powder feed rate, and density of individually sprayed materials has been established and was used to predict the density, thickness, and deposition efficiency of the combined materials. The mixture laws were found to be in good agreement with experimental results, making it possible to build up coatings with a parabolic density profile and uniform layer thickness.

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