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3D µCT and SEM Analysis of Resolidified Tips of Cored Wires Used in Twin-Wire Arc Spraying

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Abstract

In twin-wire arc spraying (TWAS), the in-flight particles are atomized from a melting bath which generates an inhomogeneous spraying plume. This inhomogeneity is due to the fact that these particles are generated by the impingement of fast continuous flowing air upon the melting tips of electrically conductive wires. This work aims to contribute to the understanding of the initiation of such particles in the TWAS process. For this purpose, cored wires filled with W-rich particles were sprayed. After interrupting the TWAS process, the tips of these cored wires were imaged by 3D µCT and scanning electron microscopy in order to analyze how the filling powder interacts with the melted part of the sheath. The analysis of the 3D tomograms shows that the resolidified melting bath of the cored wires is interspersed with both spherical and irregular-shaped W-rich particles. This irregular shape suggests a partial melting of the W-rich particles.

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Acknowledgments

The authors gratefully acknowledge the financial support of the DFG (German Research Foundation) within the Collaborative Research Center SFB 708 TP/B3.

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Authors and Affiliations

  1. RIF e.V. - Institut für Forschung und Transfer, Joseph-von-Fraunhofer-Str. 20, 44227, Dortmund, Germany

    J. Nellesen

  2. Institute of Materials Engineering, Faculty of Mechanical Engineering, Technische Universität Dortmund, Leonhard-Euler-Str. 2, 44227, Dortmund, Germany

    M. Abdulgader & W. Tillmann

  3. Helmholtz-Zentrum Geesthacht, Institute of Materials Research, Max-Planck-Str. 1, 21502, Geesthacht, Germany

    F. Beckmann

Authors
  1. J. Nellesen
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  2. M. Abdulgader
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  3. W. Tillmann
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  4. F. Beckmann
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Corresponding author

Correspondence to J. Nellesen.

Additional information

This article is an invited paper selected from presentations at the 2014 International Thermal Spray Conference, held May 21-23, 2014, in Barcelona, Spain, and has been expanded from the original presentation.

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Nellesen, J., Abdulgader, M., Tillmann, W. et al. 3D µCT and SEM Analysis of Resolidified Tips of Cored Wires Used in Twin-Wire Arc Spraying. J Therm Spray Tech 24, 55–62 (2015). https://doi.org/10.1007/s11666-014-0169-z

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  • DOI: https://doi.org/10.1007/s11666-014-0169-z

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