Microstructural and mechanical characterization of thermal sprayed nickel-alumina composite coatings

► Ni-Al2O3 composite coatings were successfully deposited using thermal spray technique. ► Content of Al2O3 in coating significantly effects the coating's microstructure ► Mechanical properties of coatings were also affected by the presence of Al2O3. ► Effect of Al2O3 content on porosity and roughness has been explained through proposed model.