Through a combination of thermal spraying with in-situ densification by means of a rolling process dense and high quality coatings can be manufactured. Thereby it is possible to produce thermal sprayed coated surfaces with a minimized post-machining process. The realisation of this kind of the manufacturing process depends on the sprayed layers themselves as well as on the coating parameters.
In this work the metallic coatings produced by arc-spraying with in-situ rolling densification process are investigated. The influence of the rolling process, the coating parameters and the coating thickness on layers morphology has been analysed. The properties of coatings under different rolling process parameters regarding porosity, wear as well as friction resistance are determined. Corresponding SEM- and LM-analyses have been conducted to understand the densification mechanisms.