Journal of Thermal Spray Technology

, Volume 28, Issue 1–2, pp 40–52 | Cite as

Variation of Heat Input and Its Influence on Residual Stresses and Coating Properties in Arc Spraying with Different Gas Mixtures

  • Michél HauerEmail author
  • Richard Banaschik
  • Werner Kroemmer
  • Knuth-Michael Henkel
Peer Reviewed


This work is about the influence of heat input on arc-sprayed coatings, caused by varying spraying patterns. The highly cavitation erosion-resistant alloys CuAl9Ni5Fe4Mn and CuMn13Al8Fe3Ni2 were arc-sprayed with a spiral-shaped pattern, using both pressurized air and a mixture of nitrogen and hydrogen. Process temperatures were recorded by thermographic imaging, and residual stresses were measured by modified hole-drilling method. Moreover, analyses of the cavitation erosion behavior and other properties were performed. Compared to previous own works, in which a meander-shaped spray pattern was used, most importantly the thermal loads, for example the maximum temperatures, during the coating buildup were lowered up to approx. 20 °C. Moreover, a more even heating of the specimens and reduced tensile stresses for both atomizing gases and materials were achieved. Furthermore, also the course of the residual stresses was changed. Hence, the dominance of the quenching stresses regarding residual stresses and coating properties, especially when spraying with pressurized air, was found to be reduced. In addition, the cavitation erosion resistance was improved severely, i.e., erosion depth was decreased up to 57%. In contrast to the aforementioned positive effects, the deposition efficiency, Young’s moduli and hardness were reduced, but still sufficient considering the application.


aluminum bronze heat input residual stress determination electronic speckle pattern interferometry cavitation-resistant coatings wire-arc spray gas shroud 



The authors would like to thank all co-workers involved in the study, namely listed in alphabetical order: R. Arndt, M. Henke, A. Novikov, C. Pust, B. Ripsch and M. Schulze. Furthermore, the authors thank F. Gärtner for his support and the helpful discussions. The research project (No. 18449 BG) of the research community Center of Maritime Technologies (CMT), Bramfelder Straße 164, 22305 Hamburg, has been funded by the AiF within the program for sponsorship by Industrial Joint Research (IGF) of the German Federal Ministry of Economic Affairs and Energy based on an enactment of the German parliament. This support is greatly acknowledged.


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Copyright information

© ASM International 2018

Authors and Affiliations

  • Michél Hauer
    • 1
    Email author
  • Richard Banaschik
    • 1
  • Werner Kroemmer
    • 2
  • Knuth-Michael Henkel
    • 3
  1. 1.Fraunhofer Research Institution for Large Structures in Production Engineering IGP - Welding Technology/Thermal SprayingRostockGermany
  2. 2.Linde AG – Linde Gases DivisionUnterschleissheimGermany
  3. 3.Chair of Joining TechnologyUniversity of RostockRostockGermany

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