Abstract: As one of the key supporting technologies of remanufacturing engineering, thermal spraying technology plays an important role in anti-wear and corrosion protection of high-end equipment parts, and is also a crucial mean to prolong service life for damaged parts. It has a broad application prospect and development space in the aspects of surface protection, dimensional recovery and additive manufacturing for equipment components in the field of aerospace, gas turbine, petrochemical and transportation. On the other hand, with the requirement constant promotion of high-end equipment for coating service performance and conti-nued development of other surface technologies, thermal spraying technology is increasingly facing the challenge of improving coating quality and performance. In terms of coating reliability, bad adhesion and internal defects in the interlayers of thermal spraying coa-ting may be causing the instability of coating quality such as poor tensile, torsion or shear resistance properties especially for the sensitive material. As a result, thermal sprayed coatings cannot be applied to high-speed reloading environment. Therefore, elucidating defect formation and structure modification mechanism of thermal sprayed coatings is the hot spot and important direction in the field of thermal spraying. Through several years of research, many scholars have characterized the formation mechanism and distributing disciplinarian of internal defects of thermal spray coating by SEM, TEM, MIP, XMT, etc. and established the mapping relation model between coating microstructure parameters and coating mechanical behavior, which proves that the inherent microscopic defects of coating are the key sticking point to limit coating performance. In order to break through the bottleneck that restricts the performance of coatings, researchers are committed to the research of theory and technology of thermal sprayed coating post-processing, and begin to improve the performance of coatings from the perspective of organizational structure modification. At present, the post processing method mainly includes remelting, annealing, hot isostatic pressing, shot peening and rolling. Those methods effectively eliminate or reduce the connected pores, enhance the boundary fusion between particles, and improve the residual stress distribution in the coating. In the end, the mechanical properties, wear resistance and corrosion resistance of the thermal sprayed coating are improved partly. From the perspective of practical application, the post processing methods adopted at present have the characteristics of high temperature. However, equipment parts for a long time in high temperature environment may make tissue degradation of the coating or substrate material, and it will lose the significance of structure modification. Overall, the application scope of existing organizational structure modification methods to thermal sprayed coating is limited. There is also no a surefire plan to improve pores, cracks or other defects in the thermal sprayed coating, and it is necessary to study and develop the new theory of thermal sprayed coating structure modification. High density pulse current treatment is an extreme non-equilibrium process for materials. Many scholars have done a lot of research in electroplasticity, electrical damage healing, and electrical grain refinement, and have achieved fruitful results. Theoretically, for inhomogeneous thermal spray coating, there will occur “flow around” phenomenon in or around the defects under the action of the high density pulse current. The electric, thermal and force effects of the pulse current may improve the uniformity of the coating, and realize the regulation of coating structure and the improvement of service performance. In this review, advantages and disadvantages of different thermal sprayed technology, mechanism of coating defect formation, the influence of defect on performance, and pros and cons of existing coating structure or performance modified methods are analyzed in detail. The electric-thermal-force effect of pulse current in metallic materials is introduced, and the feasibility and preliminary experimental verification of high density pulse current treatment in improvement of thermal sprayed coating structure and performance are analyzed and conducted.
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2018, Vol. 32 
