In many empirical studies on the structure and properties of thermally sprayed coatings, a set of two predefined parameters (e.g. porosity and elastic modulus) is correlated over a narrow range of structural variation assuming a continuous correlation function. Such a data evaluation assumes the existence of physical correlation’s between material behavior and microstructure. The experimental approach, undertaken in this study, comprises a maximum range of morphologies for starting materials with nearly identical chemical compositions to reveal the influence of microstructural changes of diverse defect species on different coating properties. The large matrix of structural and physical data is statistically correlated without any preconceived assumptions concerning the mathematical functions or the physicochemical nature of the property-microstructure-correlation’s. The divergent morphologies are realized by using different coating processes such as vacuum (VPS) and atmospheric (APS) plasma spraying, water stabilized plasma spraying (WSP), wire arc (WAS)- and flame spraying (FS), including variation of process specific parameters. The microstructure is systematically analyzed along length scales starting from defects in the micrometer down to the nanometer range. The microstructure and its anisotropy is quantified by small angle neutron scattering (SANS). The phenomenological coating behavior is successively investigated starting from basic properties such as electrical and thermal conductivity, elastic constants, residual stresses up to application oriented properties such as wear resistance. Property combinations presuming high sensitivity to microstructural changes are preferentially characterized and statistically correlated.

The pore microstructure of thermal spray coatings can be described as a combination of interlamellar pores, intralamellar cracks, and volumetric globular pores. This complex pore morphology can strongly influence the properties of the deposited layer. In this paper, the authors use a multiple small-angle neutron scattering (MSANS) technique to characterize the pore system in NiCrAlY layers. It is shown that the inter-lamella system is of utmost importance. Paper includes a German-language abstract.

Relationships between the properties of thermally sprayed nickel based alloys and their microstructure (density, porosity, oxide phase content) are investigated. Cross-property- correlation of physical properties such as electrical conductivity and elasticity were examined. The experimental results of the structures and properties of the different coatings are discussed with respect to their pore surface area obtained by small angle neutron scattering (SANS) measurements. As wide as possible range of thermally sprayed microstructures of NiCr and NiCrAlY was produced by vacuum - and atmospheric plasma spraying, flame spraying, HVOF and water stabilized plasma spraying. Commercially available powders with process specific grain size distributions were used as feedstock materials resulting in a wide range of microstructures of the coatings depending on the spraying technique and, to much less extent, on the variation of the process parameters. In this work the examination of the pore structure was carried out by optical microscopy on metallographic cross sections. Phase composition and distribution were investigated by hot gas extraction for oxygen and nitrogen determination and by Scanning Auger Microscopy on polished cross sections and fracture surfaces. The properties of the coatings were characterized by their wear (ASTM G75) behavior, reflecting application-oriented properties. Significant and varying amount of anisotropy of the coating properties - electrical conductivity and elastic modulus - was found in the sprayed microstructures. This anisotropy could be directly linked to microstructure anisotropy as characterized by Small-Angle Neutron Scattering.

Technological properties of thermally sprayed deposits are to a great extent related to the underlying microstructure. The present project aims to relate macroscopic properties of metallic coatings to their microstructure. For this purpose, thermally sprayed deposits of nickel based alloys (NiCr, NiCrAlY) were manufactured by various spraying techniques - atmospheric and vacuum plasma spraying, flame spraying, high velocity oxygen fuel and water-stabilized plasma spraying. One of the key microstructural features is the void system. This system is usually characterized by the total volume of voids, the so called porosity. An additional characteristic parameter of the void system is the specific surface area. The method of anisotropic Small Angle Neutron Scattering (SANS) in the "Porod Regime" allows the determination of the anisotropic specific surface area of the complex void system that consists of intralamellar cracks and interlamellar pores. In contrast to optical microscopy, the SANS technique is capable of resolving the pore structure down to the nanometer scale, and the measured specific surface area represents a statistically relevant average value for the whole illuminated sample volume which is usually a few mm 3 . Besides the presence of voids and cracks the performance of thermally sprayed coatings is also significantly influenced by residual stresses. In the present work residual strains were determined by the technique of neutron diffraction as well as by bending tests, i.e. laser profilometry of the substrate before and after the spraying process. The specific surface area and the residual stresses are discussed with respect to total porosity, the presence of secondary phases like oxides and wear behavior. Special attention is drawn to the anisotropy of the apparent surface area, which is discussed with respect to the anisotropy of macroscopic properties like electrical resistance.

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.