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Higher powder feed rates produced coatings with higher failure loads in three point bending, higher coating cohesion and lower coating strength anisotropy, presumably due to a peening effect.
The influence of coating cohesion, adhesion to substrate, and surface pretreatment on the corrosion behaviour of the samples is clarified.
In order to optimize the coating cohesion, various parameters were studied such as the metallic support roughness, the nature of alkoxysilanes and the drying temperature of coatings.
The remelting enhanced the coating cohesion, which led to an increase of the abrasive wear resistance and corrosion resistance, but has low influence on the sliding wear behavior, irrespective of the used remelting technology.
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As seen in the fine structure of coatings, since larger grains do not match well with each other and more voids are formed in the coating, the cohesion between grains, particles, splats and lamellae decreases by increasing SOD.
The weight loss of the as-sprayed coating with low cohesion at erosion angle of 90° was attributed to particle spalling off.
The thick coatings may lead to some loss of cohesion within the coating layer, resulting in non-uniform coating thicknesses.
As the contact current increased, the porosity and grain size of the resulting composite coating decreased, and its cohesion increased.
Modifications to the spray parameters can give rise to large, unmelted agglomerates, scattered throughout the coating and having poor cohesion to the surrounding material.
The coating failure by de-cohesion occurs as a result of de-cohesion of the ceramic layer (near the interface) with the TGO.
In the case of pure HA coatings, failure occurred due to the low cohesion of the coating, whereas the crystalline Si-HA coatings with a Si content of 1.2 at.% deformed plastically without crack formation and without detaching from the titanium substrate, which resulted in a greater coating stability.
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