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Besides conventional industrial demands, thermally sprayed coatings are increasingly used for innovative products. Such an application is the additive manufacturing of electrical components in automotive engineering. In particular, heating units are currently manufactured by a combination of various spray technologies. At present, simpler spraying processes like flame spraying are investigated with regard to their suitability as a future cost-effective alternative for fabricating isolating alumina coatings. In the present study, alumina cords were flame-sprayed using compressed air and argon as atomizing gases. The results demonstrate finely dispersed microstructures and a more regular and partially even higher surface and volume resistivity compared to past investigations in the literature as well as conventionally plasma-sprayed coatings despite a significantly reduced coating thickness. The content of alpha phase is clearly higher than for plasma-sprayed coatings, regardless of the atomizing gas used. Moreover, flame-sprayed coatings using argon reveal a higher resistivity in comparison to coatings sprayed with air. While the atomizing gas is found to mainly influence the ideal stand-off distance, the phase composition is not changed severely. In addition to the phase composition and kinematics, it can finally be concluded that humidity plays a major role in the coating properties.

Use of Different Process Gases for Manufacturing Isolating Alumina Coatings by Flame Spraying with Cords