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<p>With the escalating requirements for high-end equipment manufacturing, high-performance coating technology has emerged as a key research orientation. This study conducted innovative exploration in response to the limitations of traditional thermal spraying techniques, such as high porosity and low bonding strength of coatings, and proposed the ultrasonic-assisted supersonic plasma spraying technology. The results show that the porosity of the Ni60 coating after ultrasonic treatment decreased from 2.60% to 0.87%. The average hardness increased from 551.83 to 596.47&#xa0;HV. The average bonding strength rose from 31.99 to 42.21&#xa0;MPa. The average friction coefficient decreased from 0.4728 to 0.4444. Meanwhile, ultrasonic treatment triggered a phase transformation from an amorphous or disordered state to an ordered crystalline state, further improving the mechanical properties of the coating.</p> Graphical abstract <p></p>

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Forming mechanism and tribological properties of coatings by ultrasonic-assisted supersonic plasma spraying

  • 期刊论文

  • 发表日期：

    2026年8月2日

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  • Zhiyuan Wang,
  • Huan Chen,
  • Cong Zhang,
  • Bowen Yao,
  • Jianing Wang,
  • Zhen Li,
  • Fengyuan Bao

摘要

With the escalating requirements for high-end equipment manufacturing, high-performance coating technology has emerged as a key research orientation. This study conducted innovative exploration in response to the limitations of traditional thermal spraying techniques, such as high porosity and low bonding strength of coatings, and proposed the ultrasonic-assisted supersonic plasma spraying technology. The results show that the porosity of the Ni60 coating after ultrasonic treatment decreased from 2.60% to 0.87%. The average hardness increased from 551.83 to 596.47 HV. The average bonding strength rose from 31.99 to 42.21 MPa. The average friction coefficient decreased from 0.4728 to 0.4444. Meanwhile, ultrasonic treatment triggered a phase transformation from an amorphous or disordered state to an ordered crystalline state, further improving the mechanical properties of the coating.

Graphical abstract