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However, the high price of the spraying materials and the environmental aspects of nickel and cobalt utilization are often the limitations to their wider application.
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Besides spraying material, the coating quality depends greatly on the gas and particle dynamics.
Mixtures of Al 11Si powder and 20 vol.% SiC and 40 vol.% SiC particles in the powder feeder were used as spraying material.
The electrical properties of these coatings are impacted by the defected microstructure common to plasma sprayed materials.
Therefore, performing the fusion for a shorter time is effective for producing sprayed materials of enhanced fatigue properties.
Whether the in-situ multiphase doping, especially the metastable phase, makes the thermally sprayed materials tough or brittle is still unknown.
However, there is at present a small risk of chipping of the sprayed materials, which can be reduced by future process optimisation.
This velocity is clearly dependent on both sprayed material and substrate properties.
Low gas temperatures (< 600 °C) make it possible to maintain sprayed material in solid state during the whole process.
The axial injection mode was adopted to improve the enthalpy exchange between the plasma jet and sprayed material.
The difficulty in producing thick-formed components using this technique arises from residual stress in the sprayed material.
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