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<p>The selection of the spray torch is critical for the fabrication of suspension plasma-sprayed (SPS) coatings. Compared to a conventional plasma torch with a single cathode/anode, a cascaded torch provides more stable voltage, lower arc current and reduced plasma gas consumption. In this study, SPS coatings were fabricated using two plasma torches, both equipped with a mechanical injector. A parametric study was performed to evaluate the effects of five process parameters: suspension mass load, spray distance, plasma power, spray step and substrate roughness on coating porosity. Meanwhile, a linear model was developed. The results indicated that: (1) The porosity of SPS coatings manufactured successively by the two torches exhibited a consistent dependence on the process parameters. Specifically, total porosity decreased with increasing suspension mass load and plasma power, while it increased with greater spray distance, substrate roughness and spray step. (2) Coatings fabricated with cascaded torch exhibit lower porosity compared to those fabricated with the conventional torch. (3) The linear model shows well-fitting and has the potential to predict porosity. Additionally, the coating microstructure obtained with the cascaded torch has a distinctive plume-column microstructure.</p>

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Comparison and Porosity Prediction Modeling of SPS Coatings Fabricated via Conventional and Cascaded Torches

  • 期刊论文

  • 发表日期：

    2025年11月7日

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  • Zhoukun Shi,
  • Shaowu Liu,
  • Marie-Pierre Planche,
  • Geoffrey Darut,
  • Sihao Deng,
  • Hanlin Liao

摘要

The selection of the spray torch is critical for the fabrication of suspension plasma-sprayed (SPS) coatings. Compared to a conventional plasma torch with a single cathode/anode, a cascaded torch provides more stable voltage, lower arc current and reduced plasma gas consumption. In this study, SPS coatings were fabricated using two plasma torches, both equipped with a mechanical injector. A parametric study was performed to evaluate the effects of five process parameters: suspension mass load, spray distance, plasma power, spray step and substrate roughness on coating porosity. Meanwhile, a linear model was developed. The results indicated that: (1) The porosity of SPS coatings manufactured successively by the two torches exhibited a consistent dependence on the process parameters. Specifically, total porosity decreased with increasing suspension mass load and plasma power, while it increased with greater spray distance, substrate roughness and spray step. (2) Coatings fabricated with cascaded torch exhibit lower porosity compared to those fabricated with the conventional torch. (3) The linear model shows well-fitting and has the potential to predict porosity. Additionally, the coating microstructure obtained with the cascaded torch has a distinctive plume-column microstructure.