This present work investigates the effect of electromagnetic fields on cold spray processes by means of an induction-heating cold spray (IHCS) system. Aluminum powder was cold sprayed onto inductively heated Ti6Al-4V (Ti64) substrates. These materials were selected to minimize the mechanical contribution to coating adhesion. As a result, changes in coating adhesion strength can be attributed to improved metallic bond formation due to the effect of the electromagnetic field. Four different initial substrate surface temperatures were used in the study to assess the role of initial temperature as well. Deposition efficiency and adhesion and tensile strength measurements were recorded and are used to characterize the hybrid coating process and compare it with traditional techniques.

This study focuses on two major advantages of induction heating over flame heating in the treatment of coated boiler tubes. In both cases the induction heating process is simple, fast and effective. Firstly, we will show how the use of induction heating results in exceptionally thick and hard coatings with low porosity. Having high corrosion and wear resistant properties, the products can satisfy industry's needs for reliable coatings with a long service life. Next, the study will detail how a pipe with the coating already applied can be simultaneously bent by induction heating while the coating is melted and fused to the pipe. The result is a thicker, more even and reliable coating than that accomplished by the flame sprayed method on a bent pipe. The process is not only less cumbersome, but again provides a superior product for the market.

The aim of this study was to improve the properties of atmospheric plasma sprayed WC-Co-Ni coatings by post treatment with induction heating. The spray powders used were WC-Co-Ni composite powders, produced by adding Ni-P alloy to WC-Co powder. Induction heating applied to the coating caused fusion of the Ni-P alloy with the WC-Co-Ni coating and a strong metallurgical bond with the steel substrate. An innovation in recent experiments was the use of an antioxidant paste applied to the outer surface of the coating under treatment. This eliminated the need for working under the restrictions of a hydrogen gas environment. The properties of the treated coating were investigated regarding microstructure, hardness, adhesive strength, abrasion resistance and porosity.