Acoustic emission study on WC–Co thermal sprayed coatings

Thermally sprayed coatings contain residual stresses that are produced in the spraying process. These may reduce the coating lifetime. In order to determine the optimum spraying conditions with respect to the residual stress level present, the acoustic emission (AE) during four-point bend tests on tungsten carbide–cobalt coatings sprayed onto mild steel substrates was investigated. Samples tested at different levels of deformation were studied by means of scanning electron microscopy and AE in order to understand the cracking mechanisms. Relationships between the number and amplitude of AE events detected and the type of cracking processes occurring were established. It has been possible to compare the residual stresses caused by the effect of different spraying parameters, such as coating thickness, spraying distance and high velocity oxy-fuel gun.