A study has been made of the adherence of plasma-sprayed aluminium coatings to a wide range of metallic substrates to examine whether the mechanism previously put forward by the authors for steel substrates is of general application. It was established that aluminium adheres to metallic substrates by one of two mechanisms. At high substrate preheat temperatures, adhesion is generally by the formation of a metallurgical bond. At the lower preheat temperatures normally used, the presence of an adherent substrate oxide film with which the aluminium can react is necessary for adequate adhesion.
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