Tribological behavior of plasma sprayed carbon nanotubes reinforced TiO2 coatings

Intrinsic structural limitations of plasma-spray TiO₂ coating deteriorate its wear resistance. Herein, CNTs are incorporated in the coating to assess their effects on the microstructure and tribological properties. Structurally, degradation degree of CNTs in TiO₂ matrix during plasma spraying was revealed by Raman spectroscopy. And high resolution transmission electron microscopy manifested that TiO₂/CNT interface was well bonded along with presence of notable interfacial carbothermic product Ti_nO_2n-1 at atomic scale. The phenomenon indicates a beneficial effect for transferring stress from matrix to CNTs effectively. Then, the influence of CNTs on coating’s friction behavior was investigated by zirconia ball-on-disk tribometer under dry-sliding condition. As compared to TiO₂ coating, the nanocomposite coating exhibited a moderate decrease in friction coefficient and an enormous reduction (～93.6%) in wear volume. The remarkable advance in tribological properties of the reinforced coating can be attributed to four kinds of frictional effects of CNTs: tribo-reorientation, tribo-protruding, tribo-film and tribo-degradation.     

Influence of different introduction modes of metal Ag into plasma sprayed Al2O3 coating on tribological properties

Al₂O₃ coating and Al₂O₃/Ag (10%) composite coating were prepared on the surface of GH4169 superalloy by the atmospheric plasma spraying technology. And an in-situ synthesis method was applied to introduce the Ag particles into a part of Al₂O₃ coatings to obtain Al₂O₃/Ag(synthesis) composite coating. Then, the microstructure and mechanical properties of these three Al₂O₃-based coatings were systematically studied in this work. In order to reveal the lubrication characteristics of Ag, their friction tests were carried out at room temperature (RT), 400 °C, 600 °C and 800 °C, respectively. The results showed that both microstructure and mechanical properties of Al₂O₃/Ag(synthesis) composite coating were better than that of Al₂O₃/Ag (10%) composite coating because many pores and cracks produced during the direct spraying. Although the friction coefficients of two kinds of composite coatings were close to that of Al₂O₃ coatings at RT, their wear rates were both greatly decreased due to the introduction of Ag. In addition, the lubricating performance of Ag was not enough to reduce their friction coefficients when friction temperature is lower than 600 °C. However, the friction coefficients of these composite coatings were both reduced to about 0.3 at 800 °C . At this time, the Al₂O₃/Ag(synthesis) composite coating also exhibited a lower wear rate because of its dense microstructure and excellent mechanical properties.     

Fabrication of graphene oxide reinforced plasma sprayed Al2O3 coatings

Graphene oxide (GO) reinforced Al₂O₃ ceramic coatings were prepared on the surface of medium carbon steel by plasma spraying. The microstructure of the raw materials and coatings were characterized and analyzed by XPS, XRD, Raman and SEM. The bonding strength of the coatings was studied using a scratch method. The wear resistance of the coatings was assessed by the sliding test. The results showed that, after adding GO, the porosity of the coating reduced by about 31%, the hardness increased by approximately 10%, the bonding strength improved by 250%, and the wear rate reduced by 81% (Load: 30 N) and 84% (Load: 60 N), respectively.     

Effects of solid lubricant and laser surface texturing on tribological behaviors of atmospheric plasma sprayed Al2O3-ZrO2 composite coatings

Atmospheric plasma-sprayed (APS), low-friction Al₂O₃-ZrO₂ coatings were deposited with solid lubricants, and their effects on the laser surface texturing (LST) under a lubricated condition (commercial engine oil, 5W30) were evaluated. All specimens showed a 19.6% dimple density, and the contact angle of the APS coatings after LST processing decreased by ∼19–50%. The hydrophilicity of the APS coatings improved after LST processing, and the tribological behaviors of the APS coating containing different solid lubricants were mainly observed in the abrasive grooves, spalling, microcracks, residual pores and trapped wear debris on the worn surface. The coefficient of friction for the APS coatings was affected by the solid lubricants and the LST processing. The coefficient of friction for the APS coatings (except for h-BN) when adding solid lubricants and LST processing decreased to 3.7–7.9% and 2.3–9.5%, respectively.     

Evaluation of adhesion and mechanical properties of plasma sprayed NiCrAl/Al2O3-13wt.%TiO2 coatings

Plasma sprayed NiCrAl/Al₂O₃-13wt.%TiO₂ coating was fabricated and annealed at 300–900 °C in air atmosphere. The Elastic modulus (E), micro-hardness (H_V) and fracture toughness (K_ca) were evaluated by Vickers Indentation Fracture technique. The microstructure was studied by scanning electron microscopy. It can be concluded that with the increasing of annealing temperature, E and H_V at the interface of Substrate/Bond layer (S/B) are firstly increased and retain the highest value at 600 °C then decreased with higher annealing temperatures due to the phase transformation. E of the ceramic coating rised initially with annealing temperature increasing, reached the highest value at 400 °C, and then decreased with the further increasing of the temperature. The K_ca of the S/B interface firstly increased as the heating temperature increasing, confirming the crack initiation resistance increasing after annealing with the temperature below 700 °C. However, the K_ca decreased for further annealing temperature, even lower than that of the as-sprayed coating. Thereby, a proper annealing temperature can improve the mechanical properties of the coating since the coating becomes denser, ceramic lamellar structure becomes ambiguous and cracks are partially healed.     

Comparison of dry sliding wear behavior of plasma sprayed FeCr slag coating with Cr2O3 and Al2O3-13TiO2 coatings

The microstructure and dry sliding wear performance of thermally sprayed FeCr slag coating were evaluated in comparison with those of commercially available Al₂O₃-13TiO₂ and Cr₂O₃ ceramic coating powders to assess the applicability of FeCr slag (FS) powder, fabricated from industrial waste, as a ceramic top-coating material against wear. Ceramic top coats and underlying NiCoCrAlY bond coats were deposited on AISI 316L samples via atmospheric plasma spraying (APS), and their tribological properties were assessed using a ball-on-disc test rig at room temperature. As a result, FS coating exhibited the lowest worn volume, although it has the lowest surface hardness. Tribolayer formation was observed on the surface of the samples which were subjected to dry sliding wear tests. Delamination type wear is the dominant wear mechanism for Cr₂O₃ and FS coatings, whereas local spallation areas arising from plastic deformation were observed on the surface of Al₂O₃-13TiO₂ coatings. The results suggested the applicability of FS powder as a candidate ceramic top coating material against wear.     

Bimodal microstructure toughens plasma sprayed Al2O3-8YSZ-CNT coatings

Current work pursues generating controlled bimodal microstructure by plasma spraying of micrometer-sized Al₂O₃ and nanostructured spray-dried agglomerate with reinforcement of 20 wt% of 8 mol % yttria stabilized zirconia (8YSZ) and 4 wt% carbon nanotube (CNT) as potential thermal barrier coating (TBC) on the Inconel 718 substrate. Composite coatings exhibit bimodal microstructure of: (i) fully melted and resolidified microstructured region (MR), and (ii) partially melted and solid state sintered nanostructured regions (NR). Reinforcement with 8YSZ has led to an increase in hardness from ∼12.8 GPa (for μ-Al₂O₃) to ∼13.9 GPa in MR of reinforced Al₂O₃-YSZ composite. Further, with the addition of CNT in Al₂O₃-8YSZ reinforced composite, hardness of MR has remained similar ∼13.9 GPa (8YSZ reinforced) and ∼13.5 GPa (8YSZ-CNT reinforced), which is attributed to acquiescent nature and non-metallurgical bonding of CNT with MR. Indentation fracture toughness increased from 3.4 MPam^0.5 (for μ-Al₂O₃) to a maximum of 5.4 MPam^0.5 (8YSZ- CNT reinforced) showing ∼57.7% improvement, which is due to crack termination at NR, retention of t-ZrO₂ (∼3.3 vol%) crack bridging, and CNT pull-out toughening mechanisms. Modified fractal models affirmed that the introduction of bimodal microstructure (NR) i.e., nanometer-sized- Al₂O₃, nanostructured 8YSZ and CNTs in the μ-Al₂O₃ (MR) contributes ∼44.6% and ∼72% towards fracture toughness enhancement for A8Y and A8YC coatings. An enhanced contribution of nanostructured phases in toughening microstructured Al₂O₃ matrix (in plasma sprayed A8YC coating) is established via modified fractal model affirming crack deflection and termination for potential TBC applications.     

Effect of arc current on microstructure,texturing and wear behavior of plasma sprayed CaZrO3 coatings

In order to enhance the biocompatibility of metallic implants, various ceramic coatings are currently in vogue. CaZrO₃, a promising candidate material, was deposited through plasma spraying on stainless steel (316L) substrates at arc currents of 400, 500 and 600 A. The coatings were characterized using a SEM, XRD, surface profilometers and a tribometer. It was found that the arc current had profound effects on the thickness, microstructure, phase evolution, crystallinity and wear behavior of the coatings. The cross-sectional images and fractographic analysis showed that a denser coating with better inter-splat fusion was produced at arc current of 600 A. The average roughness (Ra) of the coatings increased from 3.62 to 6.68 μm as the arc current was increased from 400 to 600 A. The feedstock (powder) and the coatings were predominantly composed of CaZrO₃ along with a minor amount of CaZr₄O₉ phase. The rise in the arc current resulted in a slight increase in the relative proportion of the CaZrO₃ phase. Also, the coating produced at arc current of 600 A exhibited highest crystallinity. The detailed XRD analysis of (002) and (200) reflections of the ferroelectric CaZrO₃ revealed the preferred orientation of crystals in the coatings. The presence of this texture is explained on the basis of shifting the unstable Zr⁴⁺ ion in oxygen octahedral cage preferably in one direction. The increase in the arc current decreased the coefficient of friction and, as a result, relatively better wear resistance was observed for the coating produced using higher arc current. Moreover, the coating fabricated using arc current of 600 A reduced the volumetric weight loss by 13 times during the wear test as compared to the substrate. Plasma sprayed CaZrO₃ coating not only enhanced the wear resistance of the stainless steel but also showed the potential to furnish a bioactive surface.     

Friction and wear behavior of microwave sintered Al2O3/TiC/GPLs ceramic sliding against bearing steel and their cutting performance in dry turning of hardened steel

An Al₂O₃/TiC/GPLs (ATG) composite ceramic tool material was fabricated by microwave sintering. The tribological properties of ATG during sliding against GCr15 bearing steel were studied, to investigate the effects of sliding speed and normal load on the friction coefficient and wear rate. In addition, the cutting performance of ATG tools for machining of hardened alloy 40Cr steel was experimentally studied and compared with those of commercial tools. The results showed that the added graphene platelets enhanced the wear resistance and reduced the friction coefficient of the tool material. Furthermore, upon adding graphene platelets, the ability of the tools to resist breakage and their cutting depth improved. The cutting length of the microwave- sintered ATG ceramic tools was approximately 125% higher than that of hot-pressed ceramic tools and 174% higher than that of cemented carbide tools.     

Microstructural,mechanical and marine water tribological properties of plasma-sprayed graphene nanoplatelets reinforced Al2O3- 40 wt% TiO2 coating

Graphene nanoplatelets (GNPs) as reinforcement in the ceramic matrix is rising continuously due to their outstanding mechanical and lubricative properties. Herein, different compositions of GNPs (0.5–2 wt%) reinforced alumina-titania coatings were prepared using atmospheric plasma spraying. The relative density of AT coating increased from 83% to 94% with just (1.5 wt%) addition of GNP. Consequently, mechanical properties i.e. hardness and elastic modulus were improved by ~77% and ~69% respectively. Fracture toughness also increased from 2.65 ± 0.95 MPa.m^1/2 to 5.85 ± 1.07 MPa.m^1/2. Furthermore, the seawater wear test, using a ball-on-disc tribometer revealed that the wear rate of AT coating decreased from ~11 × 10^?14 m³/Nm to ~4 × 10^?14 m³/Nm, whereas the coefficient of friction reduced from 0.33 ± 0.05–0.16 ± 0.03. The mechanisms involved to improve these properties, viz. GNP sandwiching, crack bridging, crack arrest, etc. GNP’s multi-layers facilitated long-term lubricity and enhanced the wear resistance properties of the coatings.     

Microstructure and mechanical properties of plasma sprayed TiC/Ti5Si3/Ti3SiC2 composite coatings with Al additions

The mass production of MAX phase coatings such as Ti₃SiC₂ and Ti₃AlC₂ using the plasma spraying method is highly challenging due to its ultra-high temperature and short reaction time. In this study, agglomerate powders of 3Ti/SiC/C/xAl with various Al contents (x = 0–1.5) were prepared to form TiC/Ti₅Si₃/Ti₃SiC₂ composite coatings using the plasma spraying technique. The effect of the Al addition on the microstructures and mechanical performances of the as-sprayed coatings was investigated. The addition of Al decreased the TiC content of the coatings while increasing their Ti₃SiC₂ content significantly. The addition of even small amounts of Al improved the MAX phase fraction of the coatings from 8.95 wt% (x = 0) to 34.05 wt% (x = 0.2) and 41.60 wt% (x = 0.5). Excess Al did not affect the Ti₃SiC₂ content of the coatings. The composite coatings showed a lamellar structure with pores and microcracks. With the addition of Al, the microhardness of the coatings increased slightly, while the fracture toughness improved significantly. The composite coatings with Al showed better wear resistance than those without Al. The wear mechanism of the coatings was a combination of adhesive wear, abrasive wear, and oxidative wear.     

Reaction behavior and wear properties of in-situ air plasma-sprayed Al2O3-TiB2 composite coatings

In this study, Al₂O₃-TiB₂ coating was successfully deposited on steel substrates by in situ plasma spraying (IPS) using H₃BO₃, Al, and TiO₂ reactants. Beside TiB₂ and Al₂O₃, Al₁₈B₄O₃₃ was formed as a by-product with ratio of about 13 wt%. The effect of milling time of reactant and the reaction behavior was also explored. Milling process for at least 10 h can promote efficiency of reaction and milling for efficient production of Al₂O₃-TiB₂ composite. Wear behavior was examined in terms of hardness, wear track width, and wear rate of the coatings with respective measured values of 797.6 HV, 1061.3 µm, and 4.2 × 10⁻³ mm³/N.m. Based on the FESEM observations, the thickness of abrasive coating was 417 µm, delamination and adhesion were the main wear mechanisms in Al₂O₃-TiB₂-coated specimens.     

Structure and properties of plasma sprayed BaTiO3 coatings after thermal posttreatment

Previously published results on electrical and mechanical properties of BaTiO₃ coatings prepared by atmospheric plasma spraying showed anomalies in their dielectric response. This paper provides a study of electrical and mechanical properties of BaTiO₃ coatings after thermal posttreatment. The spraying was carried out by a direct current gas-stabilized plasma gun. BaTiO₃ was fed into the plasma jet as a feedstock powder prepared by reactive sintering of micrometer-sized powders of BaCO₃ and TiO₂. In the next step the coatings were annealed in air. Microstructure and phase composition are reported and discussed in relation to electric and mechanical properties. Dielectric properties are reported for the radio frequency (RF) range.     

Comparative study of the corrosion resistance of thermally sprayed ceramic coatings and their bulk ceramic counterparts

A comparative study of the corrosion properties of thermally sprayed ceramic coatings (Al₂O₃, Al₂O₃–TiO₂ with different ratios, mullite, and ZrSiO₄) and their sintered bulk ceramic counterparts was performed. The coatings were deposited on corrosion-resistant steel substrates using atmospheric plasma spraying (APS) and high velocity oxy-fuel (HVOF) spraying processes. The corrosion properties were investigated in 1 N solutions of NaOH and H₂SO₄ at 85 °C, respectively. The coating microstructures and phase compositions, as well as the corrosive environment were shown to have a strong effect on the corrosion resistance of the coatings. Al₂O₃–coatings were more sensitive to these factors than Al₂O₃–TiO₂ coatings were.The corrosion resistance of the bulk ceramics was superior to that of the thermally sprayed coatings. This is mainly because the coatings exhibited specific microstructure and contained amorphous and/or metastable phases not appearing in the bulk ceramics.     

Investigation of the crystallinity of suspension plasma sprayed hydroxyapatite coatings

Hydroxyapatite coatings were deposited on stainless steel substrates. The arc current was varied to study its effect on the coating crystallinity. The crystallinity was calculated according to the XRD patterns via Jade 6.0 software and the full width at half maximum (FWHM) of Raman peak at 962 cm⁻¹. The FE-SEM images showed that HA coatings had rod-like nanostructures and agglomerated into microspheres. The XRD patterns indicated that the as-sprayed coatings were composed of HA and some decomposition phases. Micro-Raman spectroscopies demonstrated that the main phase in the coatings was HA. The results showed that the crystallinity was increased from 68.68% to 76.84% while the FWHM varied from 9.74 to 6.38 cm⁻¹, when the arc current increased from 400 A to 600 A. The selected area electron diffraction (SEAD) patterns were used to analyze the crystallinity qualitatively, and the results agreed with the conclusions of XRD and FWHM of Raman peak.     

Characterization and corrosion behavior of plasma sprayed calcium silicate reinforced hydroxyapatite composite coatings for medical implant applications

Titanium and its alloys are widely used for medical implant applications, but their corrosion in the physiological environment leads to the discharge of metal ions, which can trigger severe health issues. In the present study, calcium silicate reinforced hydroxyapatite (HA-CS) coatings were deposited on the Ti6Al4V substrate by using atmospheric plasma spray (APS) process with an aim to improve the corrosion resistance and bioactivity. The coatings were prepared by varying the weight percentage (wt %) of calcium silicate (CS) reinforcement in hydroxyapatite (HA) as Ha/x CS (x = 0, 10, 20 wt %). The SEM analysis of the pure HA coating revealed the presence of surface microcracks, whereas HA-CS coatings displayed the crack-free surface morphology. The corrosion investigation revealed that with the progressive increment of CS content in HA coating, the corrosion resistance of HA-CS coatings improved. In addition, surface roughness, porosity, microhardness and crystallinity increased with the increase of CS content in HA. The findings of this study indicate that the development of plasma sprayed HA-CS coatings is a promising approach to improve the performance of Ti6Al4V alloy for medical implant applications.     

Effect of plasma sprayed and laser re-melted Al2O3 coatings on hardness and wear properties of stainless steel

Commercially available austenic stainless steel substrate was coated with commercially available, raw Al₂O₃ powder applied by means of plasma spraying method and then re-melted with CO₂ laser beam of various parameters. Tribological and mechanical properties of the 120 J/mm and 160 J/mm laser re-melted coatings were compared with the tribological and mechanical properties of the “as-sprayed” coating. The influence of the laser beam of various parameters on the microstructure, phase constituents, and mechanical and tribological properties of the ceramic coating was investigated by means of scanning electron microscopy, light microscopy, computer tomography, X-ray diffraction technique and nanoindentation tests. The micro sliding wear performance of the coatings was tested using a nanoindenter. The study showed an improvement of the mechanical and tribological properties caused by the laser treatment. The best results were achieved for coating re-melted with 120 J/mm laser beam.     

Phase evolution in plasma sprayed Nb2O5 coatings

Nb₂O₅ polymorphism and defect chemistry depend on the temperature, pressure, atmosphere composition and the initial crystallography. Plasma spray of Nb₂O₅ is a pathway to form coatings with in-situ metastable and nonstoichiometric phases, however so far unexplored. This study aimed to understand the phase evolution of plasma sprayed Nb₂O₅ coatings, and its effect on their morphology and properties. Phase evolution from H-Nb₂O₅ in the feedstock, to T-Nb₂O₅, TT-Nb₂O₅, N-Nb₂O₅, H-Nb₂O₅, Nb₁₂O₂₉ and NbO₂ in the coatings depends on the plasma Ar/H₂ ratio and its related enthalpy. The microstructure shows a layered distribution of nonstoichiometric phases at the splat boundaries and splat cores composed of T-Nb₂O₅ or TT-Nb₂O₅. The presence and distribution of these phases are related to the thermomechanical and electrical properties. The mechanisms driving the formation of these coatings are based on the Nb₂O₅ incongruent vaporization which promote retention of nonstoichiometric phases and the rapid solidification of metastable phases.     

Phase transition and interface evolution of Al2O3/ZrO2 particles in plasma-sprayed coatings

Alumina and zirconia ceramic particles exhibit high hardness and excellent wear resistance at high temperature, and hence are used as ceramic reinforcement phases in some plasma sprayed coatings. In this study, the interface evolution of a zirconia/alumina eutectic ceramic and the phase transition of zirconia in a plasma-sprayed coating were investigated. Scanning electron microscopy and transmission electron microscopy combined with focused-ion beam and energy dispersive X-ray were used to analyze the microstructure and composition of the ceramic interface. The results showed that the eutectic ceramic particles consisted of alumina (outer) and columnar zirconia (inner) before and after the plasma spraying process. The inner zirconia part showed the martensitic transformation of t-type zirconia to stripe-like m-type zirconia. After the plasma spraying, the interface between alumina and zirconia changed significantly, which formed a new oxide layer. The phase transition mechanism in the ceramic particle and oxide layer formation mechanism at the alumina/zirconia interface were investigated.