Improved understanding of microstructure-property relationship can help to shift from experiment-based to science-based development of thermally spray deposits. This should result in shorter and less expensive development as well as in higher functionality and reliability of the deposits. Significant amount of work has been done, however, nearly always studying deposits manufactured by only one of the thermal spray techniques. Results are therefore often spray technique specific. A broad study with samples manufactured by a number of different thermal spray techniques seems to be missing yet. Relationships valid across different techniques should provide better understanding of the generic relationships. This research employs number of different techniques - flame, HVOF, plasma (APS, VPS, WSP), to generate a wide range of microstructures. Various Ni-based alloys are studied starting from a simple chemistry (Ni) and ending with complex NiCrAlY alloys. Presented results were obtained with NiCr (80% Ni, 20% Cr) feedstock. Microstructures are characterized by various techniques-OM, SEM, XRD, small-angle neutron scattering (SANS) and others - to obtain the most comprehensive set of macro to micro structural parameters available today. The wear and corrosion properties of these deposits are measured together with internal coating stresses and the most generic microstructure-property relationships are sought.

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