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The atmospheric plasma spray (APS) process for applying thin coatings on substrates has a lot of different process parameters. To evaluate which parameters have the most significant influence on the adhesive strength, a design of experience (DoE) investigation was performed. The data for the DoE analyses were generated with an own designed adhesive tensile strength test device according to EN 13144. For these experiments, the two component epoxy HTK Ultra Bond 100 was used for loading the interface of APS zinc coated steel samples. To provide a highly repeatable test setup, a special gluing device was developed to cope with the requirements of the Ultra Bond 100. Although the DoE analysis showed the expected results, the pull-off test has some weaknesses, which are shown and discussed in the present paper.

Adhesive tensile testing of atmospheric plasma sprayed zinc coating on a 1.4301 substrate