Research Progress on Porosity Reduction in Plasma Sprayed Coatings

Plasma sprayed coatings have been widely used in surface protection engineering due to the excellent properties such as wear resistance, high temperature resistance and corrosion resistance. Pores are an important structural defect of plasma sprayed coatings. Excessive pores can lead to premature detachment failure of the coatings and shorten the service life, and therefore porosity is an important indicator to evaluate the coating quality. The pore formation mechanism, influencing factors, and the effect of the pores on the coating performance are briefly discribed. The research status of the porosity reduction of plasma sprayed coatings is reviewed from the aspects such as spraying process parameter optimization, laser remelting treatment, and modification of spraying materials. Moreover, the problems and development directions in the development of plasma sprayed coatings are summarized.