The Effect of Microstructure on Acoustic and Elastic Properties in Controlled Atmosphere Plasma Sprayed Nickel

Interlamellar gaps, globular pores, and splat-to-splat interfaces are all features of the layered microstructure generated by plasma spray, which can result in a wide range of unique properties and functions through process modification and spray parameters. However, their complex and stochastic combinations have made it difficult to evaluate their individual contributions on coating properties.

This study investigates the influence of splat-to-splat interface content and quality on the acoustic and elastic properties of Controlled Atmosphere Plasma Sprayed nickel coatings. Particle size, heat treatment, spray distance, and oxide content were all varied with the intention of amplifying or isolating the direct effects of interlamellar interface density and globular porosity on the longitudinal and shear sound velocities, modulus, and observed microstructure. The effect of microstructural features on bulk properties are discussed.