Effect of nozzle configuration, gas pressure, and gas type on coating properties in wire arc spray

X. Wang, J. Heberlein, E. Pfender, W. Gerberich

Research output: Contribution to journalArticlepeer-review

77 Scopus citations


Wire arc spraying is a coating process in which minor modifications of the configuration and spray parameters can have a strong impact on coating characteristics. A study on the effects of the fluid dynamics of the atomizing gas on the coating properties is presented. Different types of nozzles, shrouds, and gases have been used to provide various flow velocities and reactive environments in the metal atomization region. The effects on particle velocity, coating density, composition, and interface characteristics between the coating and the substrate have been evaluated. It is clear that higher gas velocities improve practically all coating properties, but also increase oxide content in the coating. However, the oxidation can be drastically reduced if nonoxidizing gases are used for atomization in combination with a shroud. A discussion on the physical effects contributing to the observed adhesion improvements and interfacial properties is provided.

Original languageEnglish (US)
Pages (from-to)565-575
Number of pages11
JournalJournal of Thermal Spray Technology
Issue number4
StatePublished - Dec 1999

Bibliographical note

Funding Information:
This study was supported in part by the NSF through the Engineering Research Center for Plasma-Aided Manufacturing, grant No. EEC 8721545. The government has certain rights in this work.


Dive into the research topics of 'Effect of nozzle configuration, gas pressure, and gas type on coating properties in wire arc spray'. Together they form a unique fingerprint.

Cite this