The splashing usually occurs when a droplet impact on a substrate surface during thermal spraying, which results in the formation of splat with irregularly complicated morphology. In present study splats are formed on polished stainless steel substrate surface covered with different organic substances with different boiling points by plasma spraying under different preheating temperature of substrate in order to clarify the factors which control the splashing during droplet flattening in thermal spray process. The droplet materials used are aluminum, nickel, copper, Al2O3 and molybdenum. Three kinds of organic substances used are xylene, glycol and glycerol which are brushed on the surface of substrate before spraying. It is found that when the preheating temperature exceeds 50°C over the boiling point of organic substance brushed on substrate surface the regular disk type splats are formed in the case that no substrate melting occurs by molten droplet. When the flattening of droplet causes the melting of substrate such as the combination of Mo droplet with stainless steel substrate, the preheating of substrate has no influence on splat morphology. The evaporated gas induced splashing and substrate surface melting induced splashing models are proposed to interpret the formation of the annulus-ringed splat.

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