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Effect of metal particles oxidation during the APS on the wettability.

ABSTRACT: Investigations have been carried out to study the in flight oxidation of iron particles during Atmospheric Plasma Spray (APS) process. The molten particles are quenched by an inert gas (argon) and collected in a experimental set‐up especially developed for this purpose. With this set‐up, more than 90 wt% of the particles are collected. Investigation methods such as XRD, Mössbauer spectroscopy and SEM‐EDX are used to determine the amount and the distribution of oxide formed. The results indicate that wüstite (FeO) is present at the surface and also in the core of the particles. This oxide phase represents about 12 wt% of the collected particles and is stable over time. Sessile drop studies of molten iron on alumina and zirconia substrates are carried out to simulate the wetting of oxidized iron particles during coating formation. It is found that the oxidation state of iron particles during APS has a significant effect on the observed contact angles. A decrease of the contact angle is observed in the case of oxidized iron particles.