{"id":7449,"date":"2025-09-11T13:47:48","date_gmt":"2025-09-11T17:47:48","guid":{"rendered":"https:\/\/spraysensors.tecnar.com\/generating-oxide-free-molten-metal-droplets-by-air-plasma-spraying-enabled-by-deoxidizer-addition-to-the-feedstock-powders\/"},"modified":"2025-09-11T13:47:48","modified_gmt":"2025-09-11T17:47:48","slug":"generating-oxide-free-molten-metal-droplets-by-air-plasma-spraying-enabled-by-deoxidizer-addition-to-the-feedstock-powders","status":"publish","type":"post","link":"https:\/\/spraysensors.tecnar.com\/fr\/generating-oxide-free-molten-metal-droplets-by-air-plasma-spraying-enabled-by-deoxidizer-addition-to-the-feedstock-powders\/","title":{"rendered":"Generating Oxide-free Molten Metal Droplets by Air Plasma Spraying Enabled by Deoxidizer Addition to the Feedstock Powders"},"content":{"rendered":"<p>Thermal spray metallic coatings usually present a lamellar structure with limited lamellar interface bonding due to inevitable oxidation involved. Such microstructure not only degrades the mechanical performances of the coatings significantly but also cannot provide effective corrosion protection to the substrate. In the present paper, the recent progresses to generate oxide-free molten metallic droplets by air plasma spraying will be summarized toward to deposition of highly dense metal coatings. It is revealed that by designing the metallic spray powders containing deoxidizers such as boron or carbon based on thermodynamics theory of oxidation, the oxide-free in-flight molten metal droplets can be created in open atmosphere during air plasma spraying. The thermodynamics and kinetics for the in-flight deoxidization are presented for the deoxidizers of boron and carbon. The tests with Ni-based and Cu-based alloy coatings using boron as deoxidizer showed that the oxygen content in the coatings can be reduced to less than 0.6 wt.%. It was demonstrated with NiCrAlY, NiAl and FeAl alloys that contain element Al the coatings with low oxide contents can be deposited by APS using carbon as deoxidizer. The post-impact oxidation is mainly responsible for the introduction of oxide inclusions in these coatings. Besides deoxidizer addition, ultra-high temperature is the other necessary condition for the generation of oxide-free molten droplets. It was revealed that a minimum deoxidizer content is necessary to maintain continuous oxidation protection of alloying elements along with rapid mass transfer mechanism within molten metal droplets during the whole spray distance.<\/p>\n<p><a class=\"btn-tec black\" href=\"https:\/\/link.springer.com\/article\/10.1007\/s11666-024-01833-0\" target=\"_blank\" rel=\"noopener\">Link to publication<\/a><\/p>\n<p>Key words: Atmospheric plasma spray<\/p>\n<p><em><small>Originally published at Journal of Thermal Spray Technology (20 September 2024, Volume 33, pages 2548\u20132564)<br \/>\nBy Chang-Jiu Li, Xiao-Tao Luo, Xin-Yuan Dong, Li Zhang, Yong-Sheng Zhu, Cheng-Xin Li and Guan-Jun Yang<\/small><\/em><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Thermal spray metallic coatings usually present a lamellar structure with limited lamellar interface bonding due to inevitable oxidation involved. Such [&#8230;]<\/p>\n<p><a class=\"btn btn-secondary understrap-read-more-link\" href=\"https:\/\/spraysensors.tecnar.com\/fr\/generating-oxide-free-molten-metal-droplets-by-air-plasma-spraying-enabled-by-deoxidizer-addition-to-the-feedstock-powders\/\">Read More&#8230;<\/a><\/p>\n","protected":false},"author":22,"featured_media":7428,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[55],"tags":[],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v24.2 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Generating Oxide-free Molten Metal Droplets by Air Plasma Spraying Enabled by Deoxidizer Addition to the Feedstock Powders - Tecnar Thermal Spray<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/spraysensors.tecnar.com\/fr\/generating-oxide-free-molten-metal-droplets-by-air-plasma-spraying-enabled-by-deoxidizer-addition-to-the-feedstock-powders\/\" \/>\n<meta property=\"og:locale\" content=\"fr_FR\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Generating Oxide-free Molten Metal Droplets by Air Plasma Spraying Enabled by Deoxidizer Addition to the Feedstock Powders - Tecnar Thermal Spray\" \/>\n<meta property=\"og:description\" content=\"Thermal spray metallic coatings usually present a lamellar structure with limited lamellar interface bonding due to inevitable oxidation involved. Such [...]Read More...\" \/>\n<meta property=\"og:url\" content=\"https:\/\/spraysensors.tecnar.com\/fr\/generating-oxide-free-molten-metal-droplets-by-air-plasma-spraying-enabled-by-deoxidizer-addition-to-the-feedstock-powders\/\" \/>\n<meta property=\"og:site_name\" content=\"Tecnar Thermal Spray\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/tecnarautomation\" \/>\n<meta property=\"article:published_time\" content=\"2025-09-11T17:47:48+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/spraysensors.tecnar.com\/wp-content\/uploads\/2025\/09\/Website-library-image-3.png\" \/>\n\t<meta property=\"og:image:width\" content=\"800\" \/>\n\t<meta property=\"og:image:height\" content=\"500\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/png\" \/>\n<meta name=\"author\" content=\"Flavia Fu\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Flavia Fu\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"1 minute\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\/\/spraysensors.tecnar.com\/fr\/generating-oxide-free-molten-metal-droplets-by-air-plasma-spraying-enabled-by-deoxidizer-addition-to-the-feedstock-powders\/#article\",\"isPartOf\":{\"@id\":\"https:\/\/spraysensors.tecnar.com\/fr\/generating-oxide-free-molten-metal-droplets-by-air-plasma-spraying-enabled-by-deoxidizer-addition-to-the-feedstock-powders\/\"},\"author\":{\"name\":\"Flavia Fu\",\"@id\":\"https:\/\/spray-sensors.shany.ca\/#\/schema\/person\/34d54d027447e60a3c51e3378480de0f\"},\"headline\":\"Generating Oxide-free Molten Metal Droplets by Air Plasma Spraying Enabled by Deoxidizer Addition to the Feedstock Powders\",\"datePublished\":\"2025-09-11T17:47:48+00:00\",\"dateModified\":\"2025-09-11T17:47:48+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\/\/spraysensors.tecnar.com\/fr\/generating-oxide-free-molten-metal-droplets-by-air-plasma-spraying-enabled-by-deoxidizer-addition-to-the-feedstock-powders\/\"},\"wordCount\":297,\"publisher\":{\"@id\":\"https:\/\/spray-sensors.shany.ca\/#organization\"},\"image\":{\"@id\":\"https:\/\/spraysensors.tecnar.com\/fr\/generating-oxide-free-molten-metal-droplets-by-air-plasma-spraying-enabled-by-deoxidizer-addition-to-the-feedstock-powders\/#primaryimage\"},\"thumbnailUrl\":\"https:\/\/spraysensors.tecnar.com\/wp-content\/uploads\/2025\/09\/Website-library-image-3.png\",\"articleSection\":[\"DPV\"],\"inLanguage\":\"fr-FR\"},{\"@type\":\"WebPage\",\"@id\":\"https:\/\/spraysensors.tecnar.com\/fr\/generating-oxide-free-molten-metal-droplets-by-air-plasma-spraying-enabled-by-deoxidizer-addition-to-the-feedstock-powders\/\",\"url\":\"https:\/\/spraysensors.tecnar.com\/fr\/generating-oxide-free-molten-metal-droplets-by-air-plasma-spraying-enabled-by-deoxidizer-addition-to-the-feedstock-powders\/\",\"name\":\"Generating Oxide-free Molten Metal Droplets by Air Plasma Spraying Enabled by Deoxidizer Addition to the Feedstock Powders - 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