In plasma transferred arc welding (PTAW), the weld pool temperature often fluctuates. The spray weld layer is prone to overheating, leading to adverse effect on its performance. This study investigated the influence of spray welding current on the weld pool temperature and in turn on the microstructure, microhardness and corrosion resistance of the PTAW-Ni layer on a steel substrate. Weld pool temperature increased with increasing spray welding current and varied along the welding gun path before reaching the steady state. With increasing pool temperature, more Fe diffused from the substrate into the spray weld layer, leading to a widened fusion zone, an increased dilution rate and a decreased microhardness. The spray weld layer has a dendritic microstructure. The dendrites have a higher Cr content, while the interdendritic regions have a higher Ni content. Increasing weld pool temperature increased diffusion, resulting in reduced enrichment of the Cr and Ni elements. The increase of Fe and decrease of Cr in the spray weld layer caused the decreasing corrosion resistance.
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