Study of roughness characteristics of a coating deposited by plasma spraying

Surfaces formed by plasma spraying of a powder material typically react with other surfaces or media, which greatly depends on the quality of the sprayed coating and, in particular, on the coated surface roughness. In this study, a relationship between the granulometric composition of a powder and the coated surface roughness is established. The particle size distribution of the zirconium oxide powder and the surface roughness of the plasma sprayed coating are analyzed. The coated surface profile is measured by the profilograph, and the grain size distribution on the coated surface is determined. The sizes of surface microasperities are compared with the sizes of particles comprising both the source powder and the powder accelerated by a plasma jet and decelerated by water. The results show that there is a qualitative agreement between the sizes of surface microasperities and powder particles, and it is possible to predict the sprayed surface roughness. The established relationships make it possible to control the quality of sprayed surfaces according to technological requirements.

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