In the present work, three different atmospheric plasma sprayed (APS) alumina coatings were fabricated using three fused and crushed alumina powders of different particle size fine, medium and coarse. The influence of the particle size on thermal properties and micro-structural features of the produced coating were investigated by thermal insulation test and detailed image analysis technique, respectively. The analyzed micro-structural features include the total porosity, pore size (fine, medium, and large) and cracks. All types of cracks were considered in calculations as voids and were evaluated according to their sizes as pores. All spray parameters except the particle size were fixed throughout the spraying process. The results revealed that the fine starting powder has produced the densest coating with the lowest total porosity and that the total porosity increases with an increasing particle size. This was expected as powders of smaller particle size will reach a higher in-flight temperature and velocity than powders of bigger particle sizes as long as the same spray parameters are applied. However, a detailed image analysis investigation on the three produced coatings showed that the fraction of fine pores and cracks versus the total porosity is substantially higher in coatings produced by using fine starting powders than those produced using medium and coarse powders. In this work, a connection between the thermal insulation and the porosity fraction, which includes fine pores and cracks, was revealed.

The strength of laser joined metal and plastic hybrids is based purely on adhesion. Unpolar plastics like polypropylene depend solely on the mechanical adhesion while polar plastics like polyamide 6.6 develop covalent bonds with the metal. In this research the influence of different surface metallizations on the lap shear strength of laser joined hybrids was investigated. Sandblasted AISI 304 was used as base metal and reference. Aluminum and titanium coatings were deposited by the means of Arc-PVD. Polypropylene and polyamide 6.6 were utilized as polar und unpolar plastics. The lap shear strength of all hybrids with polyamide 6.6 was higher than the polypropylene samples. For all investigated variations of the laser power, scanning speed and the cohesive and adhesive failure modes, the samples joined with the sandblasted AISI 304 showed the highest lap shear strength. The reduction in lap shear strength for the coated samples was due to the increased difference in thermal conductivity between the plastics and the coating materials. This lead to increased warping and residual stresses. It can be concluded that the thermal properties of the metallization in laser joined metal and plastic hybrids has a high impact on the lap shear strength.

This paper investigates if the polar groups induced by a plasma treatment can increase the lap shear strength of laser joined metal and plastic hybrids. Optimal laser joining parameters for cold-rolled AISI304 – Polyamide 6.6 and sandblasted AISI304 - Polypropylene hybrids are developed. The OWRK-method was utilized to identify the change in surface free energy of a low-pressure plasma treatment. Plasma treated samples were joined and tested. The fractured surfaces were investigated via light microscopy and SEM. The arithmetic means of the plasma treated hybrids lap shear strength with polyamide 6.6 varied slightly but all measured values were within the range of the untreated samples. The lap shear strengths of the polypropylene hybrids were significantly reduced. This was attributed to an overaging and the development of low molecular weight oxidized materials which lead to a weak boundary layer. No correlation between surface free energy and the lap shear strength could be found.