Effect of Feedstock Size and its Distribution on the Properties of Detonation Sprayed Coatings

The detonation spraying is one of the most promising thermal spray variants for depositing wear and corrosion resistant coatings. The ceramic (Al₂O₃), metallic (Ni-20 wt%Cr) , and cermets (WC-12 wt%Co) powders that are commercially available were separated into coarser and finer size ranges with relatively narrow size distribution by employing centrifugal air classifier. The coatings were deposited using detonation spray technique. The effect of particle size and its distribution on the coating properties were examined. The surface roughness and porosity increased with increasing powder particle size for all the coatings consistently. The feedstock size was also found to influence the phase composition of Al₂O₃ and WC-Co coatings; however does not influence the phase composition of Ni-Cr coatings. The associated phase change and %porosity of the coatings imparted considerable variation in the coating hardness, fracture toughness, and wear properties. The fine and narrow size range WC-Co coating exhibited superior wear resistance. The coarse and narrow size distribution Al₂O₃ coating exhibited better performance under abrasion and sliding wear modes however under erosion wear mode the as-received Al₂O₃ coating exhibited better performance. In the case of metallic (Ni-Cr) coatings, the coatings deposited using coarser powder exhibited marginally lower-wear rate under abrasion and sliding wear modes. However, under erosion wear mode, the coating deposited using finer particle size exhibited considerably lower-wear rate.     

The effect of plasma spray parameters on the cavitation erosion of Al2O3-TiO2 coatings

This paper reports a study of how the choice of plasma spray parameters, used during deposition of Al₂O₃-13%TiO₂ coatings on carbon steel, influences the cavitation erosion properties of such coatings. The parameters studied are the power feeding rate and hydrogen flow rate. The surface and cross section of coatings before and after cavitation were also observed by scanning electron microscopy (SEM). The phases present in the coatings were characterized by X-ray diffraction method (XRD). The microscopic observations were used to study the inter-lamellar connection, porosity, unmelted particles and so on inside the coating. We also measured the roughness, microhardness, adhesion strength and cavitation erosion of the coatings. The XRD results showed that the coating includes different allotropes of Al₂O₃ such as α and γ. The cavitation erosion studies of the coatings were conducted by ultrasonic cavitation testing on the basis of ASTM G32 standard. It was found that cavitation erosion is accelerated around the unmelted particles and porosities. The results reveal that the cavitation resistance of the coating is determined by its microstructure and that increasing discontinuities (inside the coating) reduce its cavitation resistance. We have found that the coating obtained at hydrogen gas flow rate of 16 L/min and powder feeding rate of 20 g/min has the best cavitation resistance.     

Structural, Mechanical and Erosion Properties of Yttrium Oxide Coatings by Axial Suspension Plasma Spraying for Electronics Applications

Yttrium oxide (Y₂O₃) coatings have been prepared by axial suspension plasma spraying with fine powders. It is clarified that the coatings have high hardness, low porosity, high erosion resistance against CF₄ -containing plasma and retention of smooth eroded surface. This suggests that the axial suspension plasma spraying of Y₂O₃ is applicable to fabricating equipment for electronic devices, such as dry etching. Surface morphologies of the slurry coatings with splats are similar to conventional plasma-sprayed Y₂O₃ coatings, identified from microstructural analysis. Dense coating structures with no lamellar boundaries have been seen, which is apparently different from the conventional coatings. It has also been found that crystal structure of the suspension coatings mainly composed of metastable monoclinic phase, whereas the powders and the conventional plasma spray coatings have stable cubic phase. Mechanism of coating formation by plasma spraying with fine powder slurries is discussed based on the results.     

Yttria stabilized zirconia corrosion destabilization followed by Raman mapping

The incidence of V₂O₅ corrosion on yttria stabilized zirconia (YSZ) thermal barrier coatings has been studied as a function of application methods and powder initial granulometry. Commercial fused-and-crushed 8 wt.% yttria-stabilized zirconia was sprayed by Atmospheric Plasma Spraying (APS) and High Frequency Pulse Detonation. Hollow Spherical Powder (HOSP™) with the same composition was sprayed by APS. The coatings where covered with V₂O₅ powder and treated at 1000 °C for different times. The extent of corrosion was followed by X-ray diffraction, scanning electron microscopy and Raman micro-spectrometry. A relationship between coating porosity and corrosion resistance is explored: the HOSP coating presented deeper penetration of corrosion than the other coatings. The authors present the extended capabilities of Raman semi-quantitative phase analysis to describe the depth and density of yttria leaching by vanadia leading to YSZ destabilization.     

Electroless Ni-P and Ni-P-Al2O3 Nanocomposite Coatings and Their Corrosion and Wear Resistance

In an effort to utilize beneficial aspects of nanoparticles in providing corrosion and wear resistance, electroless Ni-P and Ni-P-Al₂O₃ nanocomposite coatings were produced. Alumina particles with various contents from 5 to 20 g/L in bath were co-deposited within Ni-P deposits on mild steel (ms) substrate. Coatings were characterized by scanning electron microscopy (SEM) for morphology, energy dispersive analysis of x-ray EDAX for analyzing elemental composition and x-ray diffractometry for investigating the structural changes of their components. Electrochemical and immersion measurements were used to analyze corrosion behavior of the coatings in 3.5% NaCl solution. Wear resistance of the coating was measured by pin-on-disc method. The results indicated that the Ni-P-Al₂O₃ coatings provide the high hardness as compare to the Ni-P coating. Corrosion and wear resistance of coatings is observed to be superior to that of ms. Corrosion protection properties of the coatings are found to be affected with continuous exposure to the electrolyte. Coating with high concentration of alumina is exhibiting high wear resistance than Ni-P coating. Wear mechanism in case of Ni-P coating appears to be adhesive type and seems to change to abrasive type on introduction of alumina.     

Mechanical and Thermal Transport Properties of Suspension Thermal-Sprayed Alumina-Zirconia Composite Coatings

Micro-laminates and nanocomposites of Al₂O₃ and ZrO₂ can potentially exhibit higher hardness and fracture toughness and lower thermal conductivity than alumina or zirconia alone. The potential of these improvements for abrasion protection and thermal barrier coatings is generating considerable interest in developing techniques for producing these functional coatings with optimized microstructures. Al₂O₃-ZrO₂ composite coatings were deposited by suspension thermal spraying (APS and HVOF) of submicron feedstock powders. The liquid carrier employed in this approach allows for controlled injection of much finer particles than in conventional thermal spraying, leading to unique and novel fine-scaled microstructures. The suspensions were injected internally using a Mettech Axial III plasma torch and a Sulzer-Metco DJ-2700 HVOF gun. The different spray processes induced a variety of structures ranging from finely segregated ceramic laminates to highly alloyed amorphous composites. Mechanisms leading to these structures are related to the feedstock size and in-flight particle states upon their impact. Mechanical and thermal transport properties of the coatings were compared. Compositionally segregated crystalline coatings, obtained by plasma spraying, showed the highest hardness of up to 1125 VHN_{3 N}, as well as the highest abrasion wear resistance (following ASTM G65). The HVOF coating exhibited the highest erosion wear resistance (following ASTM G75), which was related to the toughening effect of small dispersed zirconia particles in the alumina-zirconia-alloyed matrix. This microstructure also exhibited the lowest thermal diffusivity, which is explained by the amorphous phase content and limited particle bonding, generating local thermal resistances within the structure.     

Enhancement of Functional Ceramic Coating Performance by Gas Tunnel Type Plasma Spraying

A high-precision plasma system has been pursued for advanced thermal processing. The gas tunnel type plasma jet device developed by the author exhibits high energy density and also high efficiency. Among its various applications is the plasma spraying of ceramics such as Al₂O₃ and ZrO₂. The performance of these ceramic coatings is superior to conventional ones. Properties such as the mechanical and chemical properties of the zirconia coatings were reported in previous studies. In this study, the enhancement of the performance of functional ceramic coatings by the gas tunnel type plasma spraying method was carried out using different powders. Results show that the alumina/zirconia composite system exhibited improvements of mechanical properties and corrosion resistance. The alumina/zirconia composite coating has the potential for use as a high functionally graded thermal barrier coating. Another application of the gas tunnel type plasma is for surface modification of metals. As an example, TiN films were formed in 5 s and, thick TiN coatings were easily obtained by gas tunnel type plasma reactive spraying.     

Study on gas permeation behaviour through atmospheric plasma-sprayed yttria stabilized zirconia coating

Gas permeation behaviour through atmospheric plasma-sprayed 8 mol% yttria stabilized zirconia (YSZ) electrolyte coating was studied experimentally. YSZ coatings were fabricated using different powder feedstock. The temperature and velocity of in-flight particles during spraying were measured with a diagnostic system. The results showed that particle temperature and velocity were significantly influenced by the size of powders. The gas permeability of these coatings was estimated by a specific instrument with pure O₂, N₂ and H₂. It was found that the gas permeability was reduced by decreasing the size of powder. Gas permeation behaviour through plasma-sprayed YSZ coating was studied. Transition flow was compatible to gas permeation behaviour for all three plasma-sprayed YSZ coatings. The relationship between gas permeation behaviour and coating microstructure is discussed in this article.     

Improving Erosion Resistance of Plasma-Sprayed Ceramic Coatings by Elevating the Deposition Temperature Based on the Critical Bonding Temperature

Interlamellar bonding within plasma-sprayed coatings is one of the most important factors dominating the properties and performance of coatings. The interface bonding between lamellae significantly influences the erosion behavior of plasma-sprayed ceramic coatings. In this study, TiO₂ and Al₂O₃ coatings with different microstructures were deposited at different deposition temperatures based on the critical bonding temperature concept. The erosion behavior of ceramic coatings was investigated. It was revealed that the coatings prepared at room temperature exhibit a typical lamellar structure with numerous unbonded interfaces, whereas the coatings deposited at the temperature above the critical bonding temperature present a dense structure with well-bonded interfaces. The erosion rate decreases sharply with the improvement of interlamellar bonding when the deposition temperature increases to the critical bonding temperature. In addition, the erosion mechanisms of ceramic coatings were examined. The unbonded interfaces in the conventional coatings act as pre-cracks accelerating the erosion of coatings. Thus, controlling interlamellar bonding formation based on the critical bonding temperature is an effective approach to improve the erosion resistance of plasma-sprayed ceramic coatings.     

A2Zr2O7型稀土锆酸盐热障涂层研究进展

综述了国内外稀土锆酸盐热障涂层在制备技术,纳米涂层,涂层结构及涂层的热物理性能、力学性能及热腐蚀性能等方面的研究成果,讨论了稀土锆酸盐热障涂层在每个方面研究存在的不足。指出未来应该进一步改善稀土锆酸盐涂层的制备工艺及后处理工艺,提高涂层的结合强度,延长涂层的服役寿命,改善涂层耐腐蚀、抗烧结等性能;开发新的涂层制备工艺,重点研究各类纳米稀土锆酸盐涂层的性能;进一步提高涂层的隔热效果、服役温度及工作寿命。     

Elevated Temperature Solid Particle Erosion Performance of Plasma-Sprayed Co-based Composite Coatings with Additions of Al<Subscript>2</Subscript>O<Subscript>3</Subscript> and CeO<Subscript>2</Subscript>

In this paper, investigation into solid particle erosion behavior of atmospheric plasma-sprayed composite coating of CoCrAlY reinforced with Al₂O₃ and CeO₂ oxides on Superni 76 at elevated temperature of 600 °C is presented. Alumina particles are used as erodent at two impact angles of 30° and 90°. The microstructure, porosity, hardness, toughness and adhesion properties of the as-sprayed coatings are studied. The effects of temperature and phase transformation in the coatings during erosion process are analyzed using XRD and EDS techniques. Optical profilometer is used for accurate elucidation of erosion volume loss. CoCrAlY/CeO₂ coating showed better erosion resistance with a volume loss of about 50% of what was observed in case of CoCrAlY/Al₂O₃/YSZ coating. Lower erosion loss is observed at 90° as compared to 30° impact angle. The erosion mechanism evaluated using SEM micrograph revealed that the coatings experienced ductile fracture exhibiting severe deformation with unusual oxide cracks. Reinforced metal oxides provide shielding effect for erodent impact, enabling better erosion resistance. The oxidation of the coating due to high-temperature exposure reforms erosion process into oxidation-modified erosion process.     

High Pressure Cold Sprayed (HPCS) and Low Pressure Cold Sprayed (LPCS) Coatings Prepared from OFHC Cu Feedstock: Overview from Powder Characteristics to Coating Properties

Cold spraying enables high quality Cu coatings to be deposited for applications where high electrical and/or thermal conductivity is needed. Fully dense Cu coatings can provide an effective corrosion barrier in specific environments. The structure of cold-sprayed Cu coatings is characterized by high deformation which imparts excellent properties. Coating properties depend on powder, the cold spray process and post treatments. First of all, powder characteristics have a strong influence on the formation of pure coatings. Secondly, cold spraying provides dense, adherent, and conductive coatings by using HPCS and LPCS. Furthermore, an addition of Al₂O₃ particles to the Cu powder in LPCS process significantly improves coating properties. Also, heat treatments improve electrical conductivity. This study summarizes optimal characteristics of Cu powder optimized for cold spraying, achieving high coating quality and compares properties of HPCS Cu, LPCS Cu and Cu+Al₂O₃ coatings prepared from the same batch of OFHC Cu powder.     

Effect of the spraying process on the microstructure and tribological properties of bronze-alumina composite coatings

In the present paper, aluminum bronze-alumina composite coatings have been applied on mild steel substrate using conventional plasma spray and a new route based on cold spray techniques. The microstructure, phase distribution, microhardness, adhesion strength and tribological behavior of the composite coatings, consisting of alumina reinforcing phase distributed in a bronze matrix, were studied. Ball-on-disk dry sliding wear tests, Rubber Wheel tests and Erosion tests were conducted to examine the tribological behavior of the composite coatings. The tribological properties of the bronze coatings were improved by the addition of alumina. Friction coefficient of coatings depends strongly on the reinforcing particles content and spraying process. Wear mechanisms of the composite coatings, such as ploughing and particle delamination, were considered. In the case of abrasive wear test, the wear rate was greatly reduced due to the reinforcing ceramic particles. Relationships between size and volume fraction of the ceramic reinforcement Al₂O₃ and the wear rate are discussed. On the other hand, erosion wear behavior of coatings with higher bronze content showed the best results.     

Characterization of Nonmelted Particles and Molten Splats in Plasma-Sprayed Al2O3 Coatings by a Combination of Scanning Electron Microscopy, X-ray Diffraction Analysis, and Confocal Raman Analysis

Plasma-sprayed ceramic coatings are deposited by flattened splats together with some nonmelted particles. In this study, both nonmelted particles and molten splats in plasma-sprayed alumina coatings were examined by a combination of scanning electron microscopy, x-ray diffraction analysis, and confocal Raman analysis to aim at the comprehensive understanding and quantitative evaluation of coating microstructure. Results showed that the nonmelted particles can be clearly identified from the polished cross section due to the raised pattern morphology (with convexes) resulting from the higher hardness of the nonmelted particles than molten splats. Raman analysis revealed that there was little α-Al₂O₃ phase in the flattened splat region, which confirmed that α-Al₂O₃ phase in the coating originated only from nonmelted particles. Moreover, it is proposed that attention should be paid to the weak bonding of the nonmelted particles to surrounding flattened splats during the preparation of samples for the quantitative characterization of coating microstructure.     

激光微纳烧结处理对玻璃陶瓷涂层组织及腐蚀性能的影响

采用高温烧结、球磨破碎的方法制备出了SiO2玻璃与Cr2O3陶瓷包覆型玻璃陶瓷复合粉末.利用常规氧—乙炔火焰喷涂技术在45钢基材表面制备出了玻璃陶瓷保护涂层,并使用激光微纳烧结技术对热喷涂层进行二次处理.研究了激光微纳烧结对玻璃陶瓷涂层组织与性能的影响.结果表明,采用激光微纳烧结对玻璃陶瓷涂层进行二次处理,可提高涂层结构的致密性,使组织均匀化,减少涂层中的微孔和微裂纹;明显提高界面的结合强度和涂层的疏水性能与耐蚀性能.因此激光微纳烧结二次处理技术可以显著提高玻璃陶瓷涂层的综合性能.     

碳化硼对电弧喷涂涂层性能的影响

将碳化硼(B4C)陶瓷粉末和其它合金元素与304L不锈钢带轧制成粉芯丝材,采用电弧喷涂技术制备金属陶瓷复合涂层.研究了B4C在电弧喷涂中的应用.利用XRD,SEM对涂层的形貌、相组成和磨损表面进行了分析.利用自行设计的高温磨粒磨损装置和高温冲蚀设备分别评价了B4C对涂层耐高温磨粒磨损性能和耐高温冲蚀性能的影响.结果表明,粉芯丝材喷涂工艺良好,B4C陶瓷与粉芯中其它组分反应,可以形成含Fe3B,CrB,FexN i23-xB6,Fe23(C,B)6,(Cr,Fe)7C3和Fe3C等硬质相的复合涂层,大幅度提高了涂层的硬度和耐磨耐冲蚀性能.     

Preparation of Al2O3–ZrO2–Y2O3 Composite Coatings by a Modified Sol–Gel Technique for Thermal Barrier Application

Spatial-network Al₂O₃–ZrO₂–Y₂O₃ composite coatings were prepared by a modified sol–gel technique, so-called thermal pressure and filtration of sol–gel paint. The composite coatings were derived from a composite paint of yttria partially stabilized zirconia (YSZ) particles, Al₂O₃ particles and Al₂O₃–Y₂O₃ sol. Their microstructure showed that YSZ particles were covered with spatial-network Al₂O₃–Y₂O₃ blanket. Cyclic oxidation at 1,050 °C in air for 200 h demonstrates that the oxygen diffusion rate in the coatings could be effectively inhibited. Meanwhile, suitable coefficients of thermal expansion (CTE) gave the composite coatings better spallation resistance than that of Al₂O₃–Y₂O₃ or ZrO₂–Y₂O₃ coatings. The positive results of cyclic oxidation indicated that the composite coating can be used as an interlayer between the bond coat and the top ceramic layer in traditional TBCs. Not only the depletion rate of aluminum-rich phase in MCrAlY alloy could be slowed down by spatial-network Al₂O₃–Y₂O₃, but also different thermal expansion between thermally grown oxides layer and top layer could be relieved by suitable CTE. In this paper, the mechanisms of the inhibition of oxygen diffusion and thermal match between ceramic coating and alloy are also discussed.     

High temperature friction and wear behaviour of Ni–P–Ag–Al2O3 hybrid nanocomposite coating

Abstract

Codeposition of silver and alumina particles has been performed within an Ni–P coating on carbon steel samples by electroless deposition to form an Ni–P–Ag–Al₂O₃ hybrid nanocomposite coating. The structure of heat treated coatings was evaluated by XRD analysis. Tribological properties of the coatings were investigated by a pin-on-disc test method using a 52100 steel pin as counter body at high temperature. A 3D optical profiler was employed to measure the wear rate of the deposits. Surface morphology, cross section and wear scars of the coatings were studied by using SEM equipped with EDS analysis. The results showed that tribological properties of Ni–P–Ag–Al₂O₃ hybrid coating are similar to Ni–P–Ag conventional composite coating. Moreover, friction coefficient and wear resistance of the hybrid coating are strongly influenced by self-lubricating silver thin layers formed between mating surfaces during high temperature sliding wear.     

Effect of Annealing Temperature on Tribological Properties and Material Transfer Phenomena of CrN and CrAlN Coatings

This study evaluates the effects of annealing temperature and of the oxides produced during annealing processes on the tribological properties and material transfer behavior between the PVD CrN and CrAlN coatings and various counterface materials, i.e., ceramic alumina, steel, and aluminum. CrAlN coating has better thermal stability than CrN coating in terms of hardness degradation and oxidation resistance. When sliding against ceramic Al₂O₃ counterface, both CrN and CrAlN coatings present excellent wear resistance, even after annealing at 800 °C. The Cr-O compounds on the coating surface could serve as a lubricious layer and decrease the coefficient of friction of annealed coatings. When sliding against steel balls, severe material transfer and adhesive wear occurred on the CrN and CrAlN coatings annealed at 500 and 700 °C. However, for the CrAlN coating annealed at 800 °C, much less material sticking and only small amount of adhesive wear occurred, which is possibly due to the formation of a continuous Al-O layer on the coating outer layer. The sliding tests against aluminum balls indicate that both coatings are not suitable as the tool coatings for dry machining of aluminum alloys.     

Cold-Sprayed Ni-Al2O3 Coatings for Applications in Power Generation Industry

Cermets coatings are extensively used in energy applications both because of their high wear resistance as required, for example, in components like gas turbine sealants, and because of their specific functionality as required in solar absorbers. So far, high-temperature thermal spraying and physical vapor deposition have traditionally been used to deposit this kind of coatings. In this study, Ni-Al₂O₃ coatings have been deposited using a Kinetic^®3000 cold-spray system starting from Ni and Al₂O₃ powders blend; five blends have been prepared setting the alumina content in the feedstock to 10, 25, 50, 75, and 90 wt.%. The embedded alumina ranges between a few percent weight up to 16 and 31 wt.%, while the microhardness shows a deep increase from 175 Vickers in the case of pure Ni coatings up to 338 Vickers. The spray and coating growth mechanism have been discussed, with special attention to the fragmentation of the ceramic particles during the impact. Finally, the coating behavior at high temperature was analyzed by oxidation tests performed in air at 520 °C emphasizing a good oxidation resistance that could represent a very promising basis for application in power generation systems.