Process Optimization and Influencing Factors of Supersonic High-Energy Plasma Spraying of Al2O3-PF Composite Coatings on Polymer Matrix Composite Surface

A high-performance Al₂O₃-PF composite coating was prepared on the surface of polymer matrix composite materials using supersonic high-energy plasma spraying technology. The bonding strength between the composite coating and the matrix was used as the evaluation index. The spraying process parameters were optimized using orthogonal experimental design method. Subsequently, the optimal process was verified based on single factor experimental method, further exploring the influence mechanism of Ar flow rate, spraying current, spraying voltage, and second powder feeding position on the composite coating. Analysis shows that spray voltage, Ar flow rate, and spray current have a significant impact on the experimental results and are the main influencing factors; the second powder feeding position has a relatively small impact on the experimental results and is a secondary influencing factor.