In-situ plasma spraying: Alumina formation and in-flight particle diagnostic

In-situ plasma spraying (IPS) is a promising process to fabricate composite coatings with in-situ formed thermodynamically stable phases. In the present study, mechanically alloyed Al–12Si and SiO2 powder was deposited onto an aluminum substrate by atmospheric plasma spraying (APS) to obtain a composite coating consisting of in-situ formed alumina reinforced hypereutectic Al–18Si matrix alloy. The effects of spray parameters (arc current and spray distance) and in-flight particle characteristics (temperature and velocity) on in-situ reaction intensity (alumina and silicon) have been investigated. The results show that, in-situ alumina formation and silicon intensity strongly depend on in-flight particle characteristics, spray distance and substrate temperature.