An elevated temperature infrared emissivity ceramic coating formed on 2024 aluminium alloy by microarc oxidation

An infrared emissivity coating material containing γ-Al₂O₃ was prepared on 2024 aluminium alloy surface by the microarc oxidation (MAO) method. The microstructure of the coatings was analysed by SEM, XRD and EDS techniques. The infrared emissivity properties tested at 500 °C were investigated by an infrared radiometer based on a Fourier transform infrared spectrometer. The results show that the infrared emissivity values of coated Al samples depend on the phase composition and surface roughness of the coatings. Corresponding to increasing coatings thickness, the gradually increasing γ-Al₂O₃ content and some oxide compounds containing Si and P contribute to the higher infrared emissivity value (about 0.85) in the wavelength range of 8–20 μm. The increasing surface roughness leads to an obvious increase in emissivity from 0.2 to 0.4 at wavelength 3–5 μm.     

Corrosion behavior of titania films coated by liquid‐phase deposition on AISI304 stainless steel substrates

Fouling deposition and localized corrosion on the heat‐transfer surfaces of the stainless steel equipments often simultaneously exist, which can introduce additional thermal resistance to heat‐transfer and damage heat‐transfer surfaces. It is a good anticorrosion way to coat a barrier layer of certain materials on the metal surface. In this article, the TiO₂ coatings with nanoscale thicknesses were obtained by liquid‐phase deposition method on the substrates of AISI304 stainless steel (ASS). The coating thickness, surface roughness, surface morphology, crystal phase, and chemical element were characterized with the film thickness measuring instrument, roughmeter, atomic force microscopy, field emission scanning electron microscopy, X‐ray diffraction, and energy‐dispersive X‐ray spectroscopy analyzer, respectively. Corrosion behavior of the TiO₂ coatings was evaluated by potentiodynamic polarization, cyclic voltammograms scanning, and electrochemical impedance spectroscopy tests with the mixed corrosion solution composed of 3.5 wt. % NaCl and 0.05 M NaOH. It is shown that the TiO₂ coating is composed of the nanoparticles with smooth, crack‐free, dense, and uniform surface topography; the roughness of coating surface increases slightly compared with that of the polished ASS substrate. The anatase‐phase TiO₂ coatings are obtained when sintering temperature being varied from 573.15 to 923.15 K and exhibit better anticorrosion behavior compared with ASS surfaces. The corrosion current density decreases and the polarization resistance increases with the increase of the coating thickness. The corrosion resistance of the TiO₂ coatings deteriorates with the increase of the corrosion time. The capacitance and the resistance of the corrosion product layer between the interface of the ASS substrate and the TiO₂ coating are found after the corrosion time of 240 h. A corrosion model was introduced, and a possible new explanation on the anticorrosion mechanisms of the TiO₂ coating was also analyzed. The corrosion mechanism of the TiO₂ coating might comply with the multistage corrosion process. © 2011 American Institute of Chemical Engineers AIChE J, 58: 1907–1920, 2012     

Rare-earth modified zirconium diboride high emissivity coatings for hypersonic applications

Sharp features of hypersonic vehicles increases heat transfer to the surface during flight. This thermal energy can be reduced via increasing the radiation and conduction heat transfer away from the surface. In this study, an emissivity modifier was incorporated into an ultra-high-temperature-ceramic coating system (ZrB₂/SiC) to increase its surface radiation heat transfer rate by increasing the emissivity of the surface. The rare-earth were incorporated into the coatings via mechanical mixing Sm₂O₃ or Tm₂O₃ with ZrB₂/SiC or chemically infiltrating Sm(NO₃)₃/ethanol solution into ZrB₂/SiC. Coatings were fabricated using shrouded air plasma spray. Total hemispherical emissivity results show that the Sm(NO₃)₃ infiltrated ZrB₂/SiC coating had a higher emissivity compared to the baseline ZrB₂/SiC coatings up to 1200 °C. The thermal conductivity of all coatings presently studied was below 12 W/m/K. The presence of rare-earth in the boria-rich surface glasses formed during oxidation increases the glass evaporation rate of the coatings compared to the ZrB₂/SiC coating.     

Heat‐resistant hydrophobic–oleophobic coatings

Thermally and chemically durable hydrophobic oleophobic coatings, containing different ceramic particles such as SiO₂, SiC, Al₂O₃, which can be alternative instead of Teflon, have been developed and applied on the aluminum substrates by spin‐coating method. Polyimides, which are high‐thermal resistant heteroaromatic polymers, were synthesized, and fluor oligomers were added to these polymers to obtain hydrophobic–oleophobic properties. After coating, Al surface was subjected to Taber‐abrasion, adhesion, corrosion, and thermal tests. The effects of the particle size of ceramic powders, organic matrix, and heat on the coating material were investigated. Coating material was characterized by FTIR spectrophotometer. Surface properties and thermal resistance of the coating materials were investigated by SEM and TGA analyses. After thermal curing, contact angles of these coatings with H₂O and n‐hexadecane were measured. It was observed that coatings like ceramic particles are more resistant against scratch and abrasion than the other coatings. Also, they are harder than coatings, which do not include ceramic particles. It was seen that coatings, containing Fluorolink D10H, have high‐contact angles with water and n‐hexadecane. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 2386–2392, 2006     

Ca2+‐Doped LaCrO3: A Novel Energy‐Saving Material with High Infrared Emissivity

The present study describes the successful synthesis of a Ca²⁺‐doped LaCrO₃ ceramic with high infrared (IR) emissivity, which is important for high‐temperature applications for significant energy saving. It is demonstrated that 20 mol% Ca²⁺‐doped LaCrO₃, i.e., La_0.8Ca_0.2CrO₃, exhibited an IR emissivity as high as 0.95 in the spectral region of 3–5 μm, which was 33.8% higher than that of LaCrO₃. By using La_0.8Ca_0.2CrO₃ as IR radiation agent in surface coating of heating unit, the radiative heat transfer could be enhanced significantly. The mechanism of the high IR emissivity of La_0.8Ca_0.2CrO₃ was attributed to the following aspects: Ca²⁺ doping introduced an impurity energy level of Cr⁴⁺ into LaCrO₃ and increased the hole carrier concentration, enhancing both impurity absorption and hole carrier absorption in the IR region; moreover, the doping caused lattice distortion enhanced the lattice vibration absorption. This novel high IR emissivity ceramic shows a promising future in high‐temperature applications for the purpose of energy‐saving.     

Ca-Mn co-doping LaCrO3 coating with high emissivity and good mechanical property for enhancing high-temperature radiant heat dissipation

Two techniques, including spray drying and electrostatic spray, were applied to produce feedstocks for preparing Ca-Mn co-doping LaCrO₃ ceramic coatings with two different structures on Ni-based alloy by the atmospheric plasma spraying method. The results show that coating from feedstocks produced by spray drying exhibits lower roughness and porosity than the coating from feedstocks produced by electrostatic spray due to the full melting of smaller feedstocks. Higher proportion of melting zones is beneficial to enhance the ratio of hardness to modulus to improve wear resistance. The emissivity of the coatings with roughness from 0.65 µm to 4.6 µm is all above 0.9 in the waveband of 1–14 µm at room temperature. What’s more, structure-dependent emissivity is affected by surface roughness and pore size due to the infrared scattering. The temperature-dependent thermal infrared emissivity at 1–14 µm decreases with the increasing temperature, and is still above 0.67 at 1200 °C.     

High emissivity MoSi2–ZrO2–borosilicate glass multiphase coating with SiB6 addition for fibrous ZrO2 ceramic

To develop a high emissivity coating on the low thermal conductivity ZrO₂ ceramic insulation for reusable thermal protective system, the MoSi₂–ZrO₂–borosilicate glass multiphase coatings with SiB₆ addition were designed and prepared with slurry dipping and subsequent sintering method. The influence of SiB₆ content on the microstructure, radiative property and thermal shock behavior of the coatings has been investigated. The coating prepared with SiB₆ included the top dense glass layer, the surface porous coating layer and the interfacial transition layer, forming a gradient structure and exhibiting superior compatibility and adherence with the substrate. The emissivity of the coating with 3 wt% SiB₆ addition was up to 0.8 in the range of 0.3–2.5 μm and 0.85 in the range of 0.8–2.5 μm at room temperature, and the “V-shaped grooves” surface roughness morphology had a positive effect on the emissivity. The MZB-3S coating showed excellent thermal shock resistance with only 1.81% weight loss after 10 thermal cycles between 1773 K and room temperature, which was attributed to the synergistic effect of porous gradient structure, self-sealing property of oxidized SiB₆ and the match of thermal expansion coefficient between the coating and substrate. Thus, the high emissivity MoSi₂–ZrO₂–borosilicate glass coating with high temperature resistance presented a promising potential for application in thermal insulation materials.     

Oxidation Resistance of AlPO4 Bonded Ceramic Coating Formed on Titanium Alloy for High‐Temperature Applications

AlPO₄ based coatings were prepared on Ti‐6Al‐2Zr‐1Mo‐1V titanium alloy using aluminum phosphate as a binder and Al₂O₃/Cr₂O₃ based mixing particles as the fillers. The microstructure, phase and chemical composition of the coatings were analyzed by SEM, XRD and EDS techniques. The high temperature infrared emissivity values of coated and uncoated titanium samples were tested. The results show that the coating had a higher infrared emissivity value (>0.8) than titanium substrate (0.15–0.3) in the wide wavelength range of 5–20 mm, which is attributed to the uniform dispersion of high emissivity Al₂O₃ and Cr₂O₃ particles in the AlPO₄ binder matrix. The coated titanium samples exhibited excellent oxidation resistance performance with significantly decreased oxidation rates at 600 and 800°C. The mass gain of the coated sample kept at a low and stable constant of 0.15 mg/cm², significantly lower than that of titanium substrate (0.54 mg/cm²) when oxidized at 600°C up to 100 h.     

Infrared radiative performance and anti-ablation behaviour of Sm2O3 modified ZrB2/SiC coatings

To improve the emissivity of ZrB₂/SiC coatings for serving in more serious environment, ZrB₂/SiC coatings with varying contents of high emissivity Sm₂O₃ were fabricated using atmospheric plasma spraying. The microstructure, infrared radiative performance and anti-ablation behaviour of the modified coatings were investigated. The results showed that as the content of Sm₂O₃ increased, the density of the coatings increased because of the low melting point of Sm₂O₃. When the content of Sm₂O₃ was 10 vol%, the coating had the highest emissivity in the 2.5–5 μm band at 1000 °C, up to 0.85, because of the oxygen vacancies promoting additional electronic transitions. Due to the high emissivity, the surface temperature of the coating modified with 10 vol% Sm₂O₃ decreased by 300 °C, which led to little volatilisation of the sealing phase. Further, the mass ablation ratio of the above coating was 3.19 × 10^?4 g/s, decreasing 31% compared to that of a ZrB₂/SiC coating. The formed dense surface structure of the coatings showed considerable oxygen obstructive effects. These findings indicate that the modified coatings show considerable anti-ablation performance, which provides effective anti-ablation protection for the C/C composite substrate.     

The properties of hydroxyapatite ceramic coatings produced by plasma electrolytic oxidation

Calcium phosphate coatings produced on the surface of Ti6Al4V by plasma electrolytic oxidation (PEO) using different concentrations of hydroxyapatite (HA) in a 0.12 M Na₃PO₄ (NAP) electrolyte solution was investigated. It was found that the amount of calcium phosphate particles infiltrated into the coating layer as well as the thickness and the surface roughness of the coating increased with increasing HA concentration. The porosity of the ceramic coatings indicated an inverse relationship with the concentration of HA particles dispersed in the NAP solution. The result also demonstrates that higher scratch adhesive strength was achieved using 1.5 g/L HA solution, producing a critical load of 2099 mN, while 0 g/L HA only produced a critical load of 1247 mN. The adhesion becomes independent of thickness when the concentration of HA exceeds 1.5 g/L. The failure of the coating was characterized by large periodic hemispherical chipping, while intermittent delamination was noticed with the coating embedded with HA particles. This study demonstrate the viability of using PEO to produce a thin layer of HA ceramic coating on Ti6Al4V suitable for biomedical applications.     

Effect of nitrogen and oxygen incorporated into TMSAA plasma coating on surface‐bound heparin activity

To investigate the influence of nitrogen and oxygen incorporated into N‐trimethylsilylallyamine (TMSAA) plasma coating on heparin binding to the surfaces, four types of monomer combinations were utilized. Those combinations include TMSAA alone, TMSAA mixed with nitrogen (TMSAA + N₂), with air (TMSAA + air), and with oxygen (TMSAA + O₂). Fourier transform infrared (FTIR) spectroscopy was employed to study the coating of the bulk structure. The thickness and surface morphology of the coatings were measured using atomic force microscopy (AFM). Electron spectroscopy for chemical analysis (ESCA) and the contact angle were used to investigate the surface elemental composition and hydrophilicity, respectively. It was found that the incorporation of oxygen into the coating formation significantly increased the deposition rate of the TMSAA + O₂ coating, but the heparin activity was the least even though it made the coating surface more hydrophilic. This is considered to have resulted from the loss of nitrogen in the coating structure due to the oxygen replacement to nitrogen. The nitrogen incorporated into the coating had no noticeable effect on the heparin surface‐binding ability. The TMSAA + air plasma grafting process exhibited the best heparin attachment to the surface, which could be largely attributed to its highest surface roughness, although the nitrogen composition was decreased to some extent compared to the pure TMSAA plasma coating. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 89: 1875–1883, 2003     

Electrochemical synthesis of poly(indole‐co‐thiophene) on low‐nickel stainless steel and its anticorrosive performance in 0.5 mol L−1 H2SO4

The electrochemical synthesis of poly(indole‐co‐thiophene) copolymer coatings was achieved on low‐nickel stainless steel (LN SS) with the cyclic voltammetry technique using indole and thiophene monomers in acetonitrile medium containing lithium perchlorate. The optimization of synthesis parameters such as monomer feed ratio and various scan rates was studied and also their influence on the morphology of the copolymer coatings on LN SS. For the first time, a possible radical cationic electro‐copolymerization mechanism is also proposed in order to understand the electrochemical synthesis. The bonding and structure of the as‐synthesized coatings were characterized using Fourier transform infrared and ¹H NMR spectroscopies. The surface morphology and composition of the coatings were also assessed using scanning electron microscopy and energy‐dispersive X‐ray analysis. It was observed that changes in morphology occurred which had a marked and significant effect on the electrochemical behaviour of the coated LN SS confirmed using electrochemical techniques of potentiodynamic polarization and electrochemical impedance spectroscopy in aqueous 0.5 mol L^?1 H₂SO₄ solution. The obtained results revealed that the copolymer coatings on LN SS provided significant corrosion protection in the acid medium. It was also found that a 1:1 ratio of indole to thiophene yielded the most stable and corrosion‐protective copolymer coating. © 2013 Society of Chemical Industry     

Fiber reinforced scalelike MoSi2-borosilicate glass coating with improved contact damage resistance and thermal shock resistance

On the surface of rigid mullite fiber ceramics, MoSi₂ high emissivity coating with improved thermodynamic properties was prepared by the slurry method combined with the sol-gel method. The area and width of the cracks in the coatings crack network structure was reduced by adding fiber into the slurry. Besides, the discrete condition among scales in the scalelike crack network was improved. The morphology, contact damage resistance, thermal shock resistance, and infrared radiation characteristics of coatings were comprehensively researched. Results showed that fibers with an aspect ratio of 25–30 existed in cracks, connecting the adjacent scale areas, enhancing the bonding performance between scales, and avoiding the peeling of the coatings under an external force. As the area of the crack area reduced, the stiffness of the coatings increased. When a constant load was applied, the coatings remained intact and had a smaller residual displacement compared with coatings without fiber addition, which improved the reusability of the coatings. After 20 thermal cycles between 1300 °C and room temperature, the bonding strength of coatings was improved after adding fiber. Besides, the tensile fracture at the fiber tile indicated that the bonding strength of the coating and substrate was higher than the mechanical interlocking between the gradient layer and substrate. The total emissivity of all the coatings was higher than 0.92.     

Fabrication and performances of preceramic polymer-based high-temperature High emissivity coating

High emissivity coatings on nickel-based superalloy, with good infrared radiating ability and good high temperature resistance, were prepared at room temperature, using preceramic polymer cured at room-temperature as coating former and CeO₂ and B₄C as passive high emissivity fillers. The influences of high temperature and wind channel test on the microstructure and thermal performance of the high emissivity coating were investigated in detail. The high emissivity coating has good thermal stability and no cracking and flaking after heating at 1100 K and the wind tunnel test. The emissivity of the coating reached 0.85−0.92 between room temperature and 1100 K. The high emissivity coating on the nickel-based alloy can make the back temperature of the nickel-based alloy decrease from 686 to 646 ℃.     

Study on electrochemical behavior of Nano‐ZnO modified alkyd‐based waterborne coatings

A nano‐composite coating was formed using nano‐ZnO as pigment in different concentrations, to a specially developed alkyd‐based waterborne coating. The nano‐ZnO modified composite coatings were applied on mild steel substrate by dipping. The dispersion of nano‐ZnO particles in coating system was investigated by scanning electron microscopic and atomic force microscopic techniques. The effect of the addition of these nano‐pigments on the electrochemical behavior of the coating was investigated in 3.5% NaCl solution, using electrochemical impedance spectroscopy. Coating modified with higher concentration of nano‐ZnO particles showed comparatively better performance as was evident from the pore resistance (R_po) and coating capacitance (C_c) values after 30 days of exposure. In general, the study showed an improvement in the corrosion resistance of the nano‐particle modified coatings as compared with the neat coating, confirming the positive effect of nano‐particle addition in coatings. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Pool boiling fouling and corrosion properties on liquid‐phase‐deposition TiO2 coatings with copper substrate

Fouling on the heat transfer surfaces of industrial heat exchangers is an intractable problem, and several techniques have been suggested to inhibit fouling. Surface coatings are of such techniques by which the adhesion force between fouling and heat transfer surface can be reduced with low surface free energy thin films. In this article, liquid phase deposition was applied to coat titanium dioxide thin films on the red copper substrates with film thickness in micro‐ or nano‐meter scale. Coating thickness, contact angle, roughness, surface topography, and components were measured with X‐ray diffraction, contact angle analyzer, stylus roughmeter, scanning electron microscopy, and energy dispersive X‐ray spectroscopy, respectively. Surface free energy of coating layers was calculated based on the contact angle. Heat transfer and fouling characteristics in pool boiling of distilled water and calcium carbonate solution on coated surfaces were investigated. Heat transfer enhancement was observed on coated surfaces compared with untreated or polished surfaces due to the micro‐ and nano‐structured surfaces which may increase the number of nucleation sites. The nonfouling time on the coated surfaces is extended than that on the untreated or polished surfaces due to the reducing of the surface free energy of coated surfaces. Corrosion behavior of coated surfaces soaked in the corrosive media of hydrochloric acid, sodium hydroxide alkali, and sodium chloride salt solutions with high concentration at room temperature a few hours was also explored qualitatively. Anticorrosion results of the coated surfaces were obtained. The coatings resisted alkali corrosion within 7.2 × 10⁵ s, acidic corrosion within 3.6 × 10⁵ s and salt corrosion within 2.16 × 10⁶ s. The present work may open a new coating route to avoid fouling deposition and corrosion on the heat transfer surfaces of industry evaporators, which is very important for energy saving in the related industries. © 2010 American Institute of Chemical Engineers AIChE J, 2011     

Vapor‐Phase Transport Crystallization of Micro‐HZSM‐5 Zeolite Coatings

A novel structured catalyst of binderless micro‐HZSM‐5 zeolite coating was prepared on stainless‐steeled tubes (i.d. 2 mm) through wash coating and vapor‐phase transport (VPT) crystallization method. The subsequent crystallization of amorphous SiO₂ binders improved the coatings adhesion tremendously by more than 10 times with the least amount of binders (<20% by weight), attributed to the remarkably enhanced interlock by the formed Mordenite Framework Inverted structure between zeolite particles. Catalytic cracking of supercritical n‐dodecane (500°C, 4 MPa) was used to examine the catalytic performance of the coatings as prepared, indicating that MZC‐V0.2 exhibited a catalytic activity improvement by 8% and a decreased deactivation rate by 48%. The improved catalytic performance may result from its high acid sites amount by incorporating extra‐framework Al into HZSM‐5 framework, and the possible depressing of pore‐mouth deactivation through partial modification of surface acid sites during VPT treatment. This work provides a potential technique to prepare mechanically stable zeolite coatings with high catalytic activity but less binder usage.     

Electrochemical deposition of tantalum carbide coatings in molten LiCl‐KCl‐K2CO3

A method for the preparation of tantalum carbide (TaC) coatings on tantalum by electrochemical reduction in carbonate ions in molten LiCl‐KCl was developed. Carbide coatings were obtained on the tantalum substrate at 900°C with a bias voltage of ?1.8 V versus the graphite counter electrode. The phase composition, morphology and strength of the carbide coating were characterized by XRD, SEM, and XPS analyses, as well as scratch testing. Kinetic mechanism for the formation of TaC coatings and evolution of chemical bonds between the carbide layer and substrate were schematically discussed. The coatings consist of a single phase of TaC with a thickness of approximately 5 μm. Ta₂O₅ and tantalate derivatives in molten salt restrict TaC formation. Electro‐deoxidation of Ta substrate can favorably eliminate tantalum‐involved compounds to produce TaC. TaC coatings improve the surface strength of Ta substrate obviously. The formation of a metal‐carbon solid solution in molten salt determines the existence of excess carbon on Ta substrate. Chemical bonds on the TaC coating were investigated in comparison with those at the interface of the metal‐oxygen‐carbon and carbon film.     

In situ thermal polymerization of an ionic liquid monomer for quasi‐solid‐state dye‐sensitized solar cells

In situ thermal polymerization of a model ionic liquid monomer and ionic liquids mixture to form gel electrolytes is developed for quasi‐solid‐state dye‐sensitized solar cells (Q‐DSSCs). The chemical structures and thermal property of the monomers and polymer are investigated in detail. The effect of iodine concentration on the conductivity and triiodide diffusion of the gel electrolytes is also investigated in detail. The conductivity and triiodide diffusion of the gel electrolytes increase with the increasing I₂ concentration, while excessive I₂ contents will decrease the electrical performances. Based on the in situ thermal polymeric gel electrolytes for Q‐DSSCs, highest power conversion efficiency of 5.01% has been obtained. The superior long‐term stability of fabricated DSSCs indicates that the cells based on in situ thermal polymeric gel electrolytes can overcome the drawbacks of the volatile liquid electrolyte. These results offer us a feasible method to explore new gel electrolytes for high‐performance Q‐DSSCs. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42802.     

Tribological properties of polyimide coatings filled with PTFE and surface‐modified nano‐Si3N4

Polyimide (PI) coatings filled with PTFE and nano‐Si₃N₄ were prepared by a spraying technique and successive curing. Nano‐Si₃N₄ particles were modified by grafting 3‐aminopropyltriethoxysilane to improve their dispersion in the as‐prepared coatings. Friction and wear performances and wear mechanisms of the coatings were evaluated. The results show that the incorporations of PTFE and modified nano‐Si₃N₄ particles greatly improve the friction reduction and wear resistance of PI coating. The friction and wear performance of the composite coating is significantly affected by the filler mass fraction and sliding conditions. PI coating incorporated with 20 wt % PTFE and 5 wt % modified nano‐Si₃N₄ displays the best tribological properties. Its wear rate is more than one order of magnitude lower and its friction coefficient is over two times smaller than that of the unfilled PI coating. Differences in the friction and wear behaviors of the hybrid coatings as a function of filler or sliding condition are attributed to the filler dispersion, the characteristic of transfer film formed on the counterpart ball and the wear mechanism of the coating under different sliding conditions. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40410.