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iTSSe

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A D V A N C E D

M A T E R I A L S

&

P R O C E S S E S |

M A Y

2 0 1 5

production of a supersaturated Ni-Cr-C solid solution from

which the carbide phase can be precipitated. In previous

work, a broad range of plasma parameters were trialed to as-

sess their effect on the degree of carbide dissolution at a fixed

spray distance of 100 mm. The current work builds on the

most promising plasma parameters from those trials. Part 2 of

this article series investigates the effect of spray distance on

the compositional development in Cr

3

C

2

-NiCr coatings during

high-energy plasma spray. Coating compositions were ana-

lyzed in detail and quantified through Rietveld fitting of the

coating XRD patterns. Coating microstructural features were

correlated with the observed variations in composition. The

effect of the spray parameters and spray distance on the equi-

librium coating compositions is discussed.

Cross-sectional BSE image illustrating the dark contrast “swirl”

features in splats in which high degrees of carbide dissolution

occurred.

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