Table 2.
Thermal spray coating parameters and measured aerosol characteristics.
| Consumable Wire Type | Spray Coating Parameters | Metal Composition of Formed Aerosol (weight %)1 | MOUDI MMAD (nm) | Geometric Std. Deviation | ELPI CMAD (nm) | Particle Surface Area (μm2/cm3) |
|---|---|---|---|---|---|---|
| PMET720 (stainless steel) | 60 psi, 30 V, 200 A | Fe 82.2 + 0.24 | 306 | 2.11 | 103 | 1.54 × 106 |
| Cr 13.4 + 0.14 | ||||||
| Mn 2.37 + 0.09 | ||||||
| Zn 1.31 + 0.13 | ||||||
| Ni 0.397 + 0.14 | ||||||
| Cu 0.175 + 0.013 | ||||||
| PMET720 (stainless steel) | 50 psi, 30 V, 200 A | Fe 81.7 + 0.24 | 280 | 1.83 | 96 | 8.70 × 105 |
| Cr 14.9 + 0.19 | ||||||
| Mn 2.61 + 0.04 | ||||||
| Zn 0.354 + 0.08 | ||||||
| Ni 0.260 + 0.04 | ||||||
| Cu 0.160 + 0.002 | ||||||
| PMET731 (stainless steel) | 60 psi, 30 V, 200 A | Fe 66.3 + 0.56 | 310 | 1.94 | 104 | 1.03 × 106 |
| Cr 26.2 + 0.57 | ||||||
| Al 5.32 + 0.15 | ||||||
| Mn 1.02 + 0.02 | ||||||
| Zn 0.237 + 0.05 | ||||||
| Ni 0.289 + 0.03 | ||||||
| Cu 0.139 + 0.03 | ||||||
| PMET885 (Ni-based) | 60 psi, 30 V, 250 A | Ni 96.9 + 0.63 | 316 | 1.94 | 111 | 1.12 × 106 |
| Al 1.69 + 0.03 | ||||||
| Zn 1.06 + 0.32 | ||||||
| Fe 0.699 + 0.11 | ||||||
| PMET876 (Ni-based) | 60 psi, 30 V, 200 A | Ni 55.5 + 0.46 | 367 | 2.13 | 135 | 3.70 × 105 |
| Cr 17.4 + 0.26 | ||||||
| Mo 17.0 + 0.58 | ||||||
| Fe 5.08 + 0.15 | ||||||
| Mn 3.40 + 0.07 | ||||||
| Al 0.911 + 0.04 | ||||||
| Zn 0.649 + 0.14 | ||||||
| PMET540 (Zn- based) | 60 psi, 23 V, 200 A | Zn 99.4 + 0.24 | 378 | 1.89 | 165 | 9.15 × 105 |
| Ni 0.325 + 0.16 | ||||||
| Fe 0.235 + 0.14 |
1
Relative to all metals analyzed; values are means + standard error (n = 4).