1 Materials Engineering Dept., University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.

2 State Company for Steel Industries, Ministry of Industry and Minerals, Baghdad, Iraq

3 Materials Engineering Dept., University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq


The effect of some parameters on the diffusion depth of the Ni-Cu coating layer on 52 low carbon steel samples using flame thermal spraying was investigated. In this research, coating-powder particle (1926.6 nm) was used, spraying gases pressure (0.5, 1bar) for oxygen and acetylene was implemented, and the temperature of the sprayed coating layer on the substrate was in the range (500- 750 C°). Diffusion cross-section was observed by using an optical microscope. The microstructure and phase analysis of the coating layer was observed by using X-ray diffraction (XRD), and SEM respectively. At standoff distance was 125 mm, powder feeding rate 30g/ min, substrate surface roughness N10 µm, and the gun carrier transverse velocity 50 mm/m, the results showed high and homogeneous diffusion zone between the coating layer and the substrate (image 1f and 3f), however, image 2f exhibit the porosity in the boundary between the coating layer and the substrate.


  • Ni-Cu coatings were perfectly deposited on 52 low carbon steel by using the flame thermal sprayed method.
  • Optical microscope showed that the experiment number six shows a homogeneous diffusion zone.
  • X-ray diffraction (XRD) of the coating layer revealed Cu and Ni-Cu phases which can acts as a protection barrier.
  • SEM analyses informed that the coated sample has a homogeneous structure   and covers all the substrate material. 


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