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The technique of multiple small-angle neutron scattering (MSANS) was applied to thermally sprayed metallic deposits. The samples are technologically relevant Ni-based NiCrAlY coatings manufactured by different spray techniques (atmospheric and water-stabilised plasma spraying, flame spraying). MSANS measurements were made in directions parallel and perpendicular to the surface plane. Based on empirical considerations and on the analysis of SEM micrographs of coating cross-sections, the complex microstructures were modelled in terms of three distinct void systems. Employing a recent MSANS formalism, the experimental beam-broadening as a function of incident wavelength was used to derive the model parameters under the constraints of MSANS anisotropy, total measured porosity, and total internal surface area. The surface area was obtained from small-angle neutron scattering analysis in the Porod regime.

Characterisation of thermally sprayed metallic NiCrAlY deposits by multiple small-angle scattering