In this work, plasma coatings of NiAl10 and NiAl40 on magnesium alloy AZ91 substrate were prepared by the hybrid plasma spraying system WSP®-H 500. The both plasma sprayed coatings of NiAl10 and NiAl40 have metallurgical bond. The thicknesses of microstructures in the cross-section of NiAl10 and NiAl40 plasma sprayed coatings prepared by 9 passes were 374 and 440 μm respectively. Adhesion test of plasma sprayed layers was performed using a modified ASTM C 633 standard. The tensile adhesion strength values are 24.7 MPa for NiAl10 coatings and 12.3 MPa for NiAl40 coatings. Abrasion resistance according to Slurry Abrasion Response (SAR) test of NiAl40 layers had similar values (0.12 g/cm2)in a comparison with the uncoated AZ91 (0.126 g/cm2). Layers NiAl10 had greater weight losses (0.175 g/cm2) than uncoated AZ91. Microhardness of plasma coating of NiAl40 is several times greater than microhardnesses of plasma coating of NiAl10 and uncoated substrate AZ91.Keywords: Plasma spraying, nickel alloys, adhesion strength, wear resistance
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