Effect of Torch Power and Thickness on APS Al2O3 Coatings on 100Cr6 Bearing Steel: Microstructure, Adhesion and Flexural Response

This research examines how atmospheric plasma spraying torch power and coating thickness jointly affect the adhesion strength, microstructure, porosity, and flexural behavior of Al2O3 coatings on 100Cr6 steel substrates. Optical microscopy, SEM and EDS mapping, 3D surface-roughness analysis, Vickers hardness testing (HV2) on polished cross-sections, and three-point bending of extracted beams were employed to develop a processing–structure–property map. This multi-technique approach enables the cross-validation of processing–structure–property relationships and supports a robust identification of the optimal power–thickness condition by jointly considering porosity (densification), adhesion strength, flexural response and failure mode. All conditions resulted in an average surface roughness Ra of approximately 1.0 µm. Increasing torch power to 45 kW generally reduced cross-sectional porosity, except at 500 µm, where globular pores appeared. Hardness (HV2) increased with power and peaked at the intermediate thickness (500 µm); adhesion up to 63 MPa was recorded for the 300 µm/45 kW coating. Flexural strength was highest at 500 µm and was consistently greater at 45 kW than at 39 kW. Fractography showed a shift in failure mode from interface-driven delamination at 39 kW to more cohesive, tortuous intra-coating cracks at 45 kW, aligned with improved splat bonding and crack-path deflection. An intermediate thickness of 500 µm deposited at 45 kW is thus identified as an optimal condition to balance densification and crack-path tortuosity, leading to enhanced hardness and flexural performance.