Nowadays wire arc spraying of chromium steel has gained an important market share for corrosion and wear protection applications. In order to optimize the process parameters and to evaluate the effect of the spray parameters as well DoE based experiments have been carried out. In this paper, the effects of the process parameters spray current, voltage and atomizing gas pressure on the particle jet properties like mean particle velocity, mean particle temperature and the plume are presented. To monitor these values the AccuraSpray system was used. The properties of the coatings with regards to the morphology, the composition and phase formation are included as well.

These investigations are part of the development of new power supplies and the enhancement of spray parameter range. As a result of these experiments the spray parameters can be adjusted according to the requirements of the chromium steel coatings.