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Oxide Free Wire Arc Sprayed Coatings—An Avenue to Enhanced Adhesive Tensile Strength

Conventionally, thermal spraying processes are almost exclusively carried out in an air atmosphere. This results in oxidation of the particles upon thermal spraying, and thus, the interfaces of the splats within the coating are oxidized as well. Hence, a full material bond strength cannot be established. To overcome this issue, a mixture of monosilane and nitrogen was employed in the present study as the atomising and environment gas. With this approach, an oxygen partial pressure corresponding to an extreme-high vacuum was established in the environment and oxide-free coatings could be realized. It is shown that the oxide-free particles have an improved substrate wetting behaviour, which drastically increases the adhesive tensile strength of the wire arc sprayed copper coatings. Moreover, the altered deposition conditions also led to a significant reduction of the coating porosity.