Many thermal spray processing parameters affect deposited coating properties. Several studies (1-2) have been conducted to learn how the deposited coating microstructure is affected by these deposition parameters. This work investigates how; through, the application of pulsed ultrasonic power, coating density and microstructure may be influenced. Systems studied were iron oxide, alumina and nickel. The affect of pulsed ultrasonic power (up to four kW) and phonon frequency (up to 17 MHz) on coating density was determined and the resultant coatings were characterized via scanning electron microscopy. The application of ultrasonic power was found to influence coating density. Coating density could be increased or decreased depending on the applied ultrasonic frequency and power.
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