Experimental studies of twin-wire electric arc sprayed zinc/aluminum alloycoatings

An experimental study of twin-wire electric are spraying of zinc/aluminum a lloy coatings demonstrates the suitability of the systems for anticorrosion applications. Experiments were conducted using Box-type, fractional-factor ial designs. The process parameters that were varied include nozzle diamete r, current, spray distance, and system pressure. The experiments were desig ned to display the range of processing conditions and their effect on the c oating. The coatings were characterized with bond strength and deposition e fficiency tests and optical metallography. Coating characteristics were qua ntified with respect to roughness, porosity, thickness, bond strength, and microstructure. Performance evaluation of the coatings was quantified with accelerated corrosion testing. A parameter-property-performance relationshi p has been developed for each material system. This paper presents the resu lts of material systems 85Zn/15Al and 70Zn/30Al.