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Pores, which have remarkable influence on many properties of coatings such as wear resistance, anti-corrosion, thermostability, etc. are the natural structure formed in plasma sprayed coatings, and have been regarded as one of the most important indexes in spraying parameter refining. Hence, it is of great significance to comprehensively characterize the structural parameters of pores in the coatings, especially for the accurate evaluation of the coating quality. In this paper, probability statistics method, fractal method and digital image analysis technique are used to investigate the number, shape, size and distribution of the pores. Besides, the formation mechanism of the coatings is discussed. First, Fe-based coatings with different porous structures are fabricated at different spraying powers. Second, the digital image analysis technique is used to process the scanning electron microscope micrographs of coatings with different pores. Finally, the Weibull statistical model is utilized to analyze the distribution law of perimeter and area of the pores. The power law of area-perimeter which originats from fractal theory is employed to quantitatively characterize the irregular morphology of the pores. In order to investigate the formation mechanism of the pores, the Spraywatch is used to monitor the flying condition of the spraying particles in the whole experimental process. The result shows that fractal dimension (FD) can characterize the irregular morphology of pores. The area becomes bigger and the border becomes more complex when the FD is larger, and there is a good relationship between FD and the formation mechanism of the pores. Besides, the areas and perimeters of the pores obey the binomial Weibull distribution obviously, namely, the shape parameter (β) turns larger as pore size becomes smaller. The spraying power has a different effect on the distribution law of pore size. With the increase of the spraying power, the molten state is improved. As a result, the size of the pore decreases obviously. When the area or the perimeter is less than their corresponding characteristic values, the probability density of the pores with the same area or perimeter becomes closer to each other, which indicates that the effect of spraying power on the pores of small size is much lower.
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Keywords:
- plasma spray /
- Weibull model /
- fractal dimension /
- pores
[1] Piao Z Y, Xu B S, Wang H D, Pu C H 2011 Appl. Surf. Sci. 257 2581
[2] Stewart S, Ahmed R, Itsukaichi T 2004 Wear 257 962
[3] Kang J J, Xu B S, Wang H D, Wang C B 2014 Tribol. Inter. 73 128
[4] Wang H J 2006 Questions and Answers about Thermal Spraying Technology (Beijing: National Defense Industry Press) p195 (in Chinese) [王海军 2006 热喷涂技术问答 (北京: 国防工业出版社) 第195页]
[5] Shinozaki M, Clyne T W 2013 Acta Mater. 61 579
[6] Mustafa G G, Gultekin G 2015 Surf. Coat. Technol. 276 202
[7] Gómez C A, Alvarez L C, Coca R, Martínez P R, Concheiro A, Gómez A J L 2009 Acta Mater. 57 295
[8] Zhang X C, Xu B S, Wu Y X, Xuan F Z, Tu S T 2008 Appl. Surf. Sci. 254 3879
[9] Zhou Y 2010 Methods of Material Analysis (Beijing: China Machine Press) p223 (in Chinese) [周玉 2010 材料分析方法 (北京: 机械工业出版社) 第223页]
[10] Jon A E, Soumyajyoti B, Bikas K C 2010 Phys. Rev. E 82 041124
[11] Thomas S, Dietrich E W, Thorsten P 2008 Phys. Rev. Lett. 100 2008002
[12] Farkas D, Willemann M, Hyde B 2005 Phys. Rev. Lett. 94 165502
[13] Dong X J, Hu Y F, Wu Y Y, Zhao J, Wan Z Z 2010 Chin. Phys. Lett. 27 044401
[14] Cai J C, Guo S L, You L J, Hu X Y 2013 Acta Phys. Sin. 62 014701 (in Chinese) [蔡建超, 郭士礼, 游利军, 胡祥云 2013 62 014701]
[15] Cai J C 2014 Chin. Phys. B 23 044701
[16] Li F J, Li L, Stott F H 2004 Thin Solid Films 453-454 229
[17] Zhang X C, Xu B S, Xuan F Z, Wang H D, Wu Y X, Tu S T 2009 J. Alloy. Compd. 467 501
[18] Zhang X C, Xu B S, Xuan F Z, Wang H D, Wu Y X 2009 J. Alloy. Compd. 473 145
[19] Wang H D, Ma J, Li G L, Kang J J, Xu B S 2014 Appl. Surf. Sci. 314 468
[20] Li F J, Ding C X 2000 Thin Solid Films 376 179
[21] Zhu H, Ji C C 2011 Fractal Theory and Its Application (Beijing: Science Press) p51 (in Chinese) [朱华, 姬翠翠 2011 分形理论及其应用 (北京: 科学出版社) 第51页]
[22] Piao Z Y, Xu B S, Wang H D, Pu C H 2010 Tribol. Inter. 43 252
[23] Zhang Z Q, Wang H D, Xu B S, Zhang G S 2015 Surf. Coat. Technol. 261 60
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[1] Piao Z Y, Xu B S, Wang H D, Pu C H 2011 Appl. Surf. Sci. 257 2581
[2] Stewart S, Ahmed R, Itsukaichi T 2004 Wear 257 962
[3] Kang J J, Xu B S, Wang H D, Wang C B 2014 Tribol. Inter. 73 128
[4] Wang H J 2006 Questions and Answers about Thermal Spraying Technology (Beijing: National Defense Industry Press) p195 (in Chinese) [王海军 2006 热喷涂技术问答 (北京: 国防工业出版社) 第195页]
[5] Shinozaki M, Clyne T W 2013 Acta Mater. 61 579
[6] Mustafa G G, Gultekin G 2015 Surf. Coat. Technol. 276 202
[7] Gómez C A, Alvarez L C, Coca R, Martínez P R, Concheiro A, Gómez A J L 2009 Acta Mater. 57 295
[8] Zhang X C, Xu B S, Wu Y X, Xuan F Z, Tu S T 2008 Appl. Surf. Sci. 254 3879
[9] Zhou Y 2010 Methods of Material Analysis (Beijing: China Machine Press) p223 (in Chinese) [周玉 2010 材料分析方法 (北京: 机械工业出版社) 第223页]
[10] Jon A E, Soumyajyoti B, Bikas K C 2010 Phys. Rev. E 82 041124
[11] Thomas S, Dietrich E W, Thorsten P 2008 Phys. Rev. Lett. 100 2008002
[12] Farkas D, Willemann M, Hyde B 2005 Phys. Rev. Lett. 94 165502
[13] Dong X J, Hu Y F, Wu Y Y, Zhao J, Wan Z Z 2010 Chin. Phys. Lett. 27 044401
[14] Cai J C, Guo S L, You L J, Hu X Y 2013 Acta Phys. Sin. 62 014701 (in Chinese) [蔡建超, 郭士礼, 游利军, 胡祥云 2013 62 014701]
[15] Cai J C 2014 Chin. Phys. B 23 044701
[16] Li F J, Li L, Stott F H 2004 Thin Solid Films 453-454 229
[17] Zhang X C, Xu B S, Xuan F Z, Wang H D, Wu Y X, Tu S T 2009 J. Alloy. Compd. 467 501
[18] Zhang X C, Xu B S, Xuan F Z, Wang H D, Wu Y X 2009 J. Alloy. Compd. 473 145
[19] Wang H D, Ma J, Li G L, Kang J J, Xu B S 2014 Appl. Surf. Sci. 314 468
[20] Li F J, Ding C X 2000 Thin Solid Films 376 179
[21] Zhu H, Ji C C 2011 Fractal Theory and Its Application (Beijing: Science Press) p51 (in Chinese) [朱华, 姬翠翠 2011 分形理论及其应用 (北京: 科学出版社) 第51页]
[22] Piao Z Y, Xu B S, Wang H D, Pu C H 2010 Tribol. Inter. 43 252
[23] Zhang Z Q, Wang H D, Xu B S, Zhang G S 2015 Surf. Coat. Technol. 261 60
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