Sliding wear characteristics of plasma-sprayed Cr2O3 coatings with incorporation of metals and ceramics

Different additives (metals, ceramics, and metal/ceramic assembles) were incorporated into chromium oxide (Cr₂O₃) coatings to improve its wear resistance. The doping or co-doping effects were compared in terms of the microstructure, phase composition, microhardness and sliding wear properties of plasma-sprayed Cr₂O₃-7wt.% Mo, Cr₂O₃-7wt.% Nb₂O₅, Cr₂O₃-4wt.% MoO₃-3wt.% Mo, and Cr₂O₃-4wt.% Nb₂O₅-3wt.% Mo coatings. Under the low sliding loads, the composite coatings mated with WC-Co counterparts have lower friction coefficients than those against Si₃N₄, which are inverse with their microhardnesses, but more obvious fatigue wear characteristics. Under the high sliding loads, Mo/Nb₂O₅ co-doped Cr₂O₃ coating (CNM) has the best wear resistance than other coatings, due to the delaying co-effects of crack formation and propagation on basis of the crack deflection and the toughening effects of Mo additives and the high hardness of Nb₂O₅ additives. As the reciprocating sliding loads exceed the critical stress of brittle Cr₂O₃-based coatings, the coating detachments occur, displaying obvious fatigue wear characteristics.     

Wear resistance of chromium oxide nanostructured coatings

Nanostructured plasma-sprayed chromium oxide ceramic coatings, with a higher wear resistance than coatings obtained using micrometric powder as starting material have been developed. The influence of the starting powder, i.e. Cr₂O₃ fused crushed powders and Cr₂O₃ nanopowders having grains size of 100 nm, has been investigated. The nanopowders are reconstituted into spherical micrometer sized granules by the spray-drying process before plasma spraying. It is shown that due to their specific microstructure the wear resistance of the nanostructured coatings is more than 20 times higher compared to the coatings obtained using micrometric powder.     

Effect of microstructure and mechanical properties on wear behavior of plasma-sprayed Cr2O3-YSZ-SiC coatings

In this study, the microstructure and mechanical properties of the atmospheric plasma-sprayed Cr₂O₃ (C), Cr₂O₃-20YSZ (CZ), and Cr₂O₃-20YSZ-10SiC (CZS) coatings were evaluated and also compared with each other, so as to explain the coatings wear behavior. Microstructural evaluations included X-ray diffraction (XRD), field emission scanning electron microscopy (FE-SEM) equipped with energy dispersive X-ray spectroscopy (EDX) and porosity measurements. Mechanical tests including bonding strength, fracture toughness, and micro-hardness tests were used to advance our understanding of the correlation between the coatings properties and their wear behavior. The sliding wear test was conducted using a ball-on-disk configuration against an alumina counterpart at room temperature. Addition of multimodal YSZ and subsequent SiC reinforcements to the Cr₂O₃ matrix resulted in an increase in the fracture toughness and Vickers micro-hardness, respectively. It was found that the composite coatings had comparable coefficients of friction with pure Cr₂O₃ coatings. When compared with the C coating, the CZ and CZS composite coatings with higher fracture toughness exhibited superior wear resistance. Observation of the wear tracks of the coatings indicated that the lower wear rates of the CZ and CZS coatings were due to the higher plastic deformation of the detached materials. In fact, improvement in the wear resistance of the composite coatings was attributed to a phase transformation toughening mechanism associated with tetragonal zirconia which created more ductile tribofilms during the wear test participated in filling the pores of coatings.     

Corrosive wear behavior of HVOF-sprayed micro-nano-structured Cr3C2–NiCr cermet coatings under aqueous media

A novel micro-nano-structured Cr₃C₂–NiCr cermet coating was prepared on 316L stainless steel by high-velocity oxygen fuel spraying technology (HVOF). Cermet coatings with different contents of micro-and nano-sized Cr₃C₂ particles as the hard phase and a NiCr alloy matrix as the bonding phase were prepared and characterized in terms of porosity, microhardness, and corrosive wear resistance in a 3.5% NaCl solution and artificial seawater. Compared to nanostructured coatings, micro-nano-structured coatings avoid decarburization and reduce nanoparticle agglomeration during the spray process, and mechanical and electrochemical properties were improved in comparison with those of conventional coatings. The micro-nano-structured Cr₃C₂–NiCr coating rendered low porosity (≤0.34%) and high microhardness (≥1105.0HV_0.3). The coating comprising 50% nano-sized Cr₃C₂ grains exhibited the best corrosive wear resistance owing to its densest microstructure and highest microhardness. Furthermore, compared to static corrosion, the dynamic corrosion of the coatings led to more severe mechanical wear, because corrosion destroyed the coating surface and ions promoted corrosion to invade coatings through the pores during corrosion wear.     

Microhardness and wear resistance of Al2O3-TiB2-TiC ceramic coatings on carbon steel fabricated by laser cladding

Al₂O₃-TiB₂-TiC ceramic coatings with high microhardness and wear resistance were fabricated on the surfaces of carbon steel substrates by laser cladding using different coating formulations. The microstructures of these ceramic coatings with the different coating formulations were investigated using X-ray diffraction, scanning electron microscopy, and energy dispersive spectrometer. The wear resistance and wear mechanism were analyzed using Vickers microhardness and sliding wear tests. The results showed that when the amount of independent Al₂O₃ was increased to 30%, the ceramic coatings had a favorable surface formation quality and strong metallurgical bond with the steel matrix. The cladding layer was uniformly and densely organized. The black massive Al₂O₃, white granular TiB₂, and TiC distributed on the Fe substrate significantly increased the microhardness and wear resistance. The laser cladding ceramic coating had many hard strengthening phases, and thus resisted the extrusion of rigid particles in frictional contact parts. Therefore, the wear process ended with a “cutting-off” loss mechanism.     

Tribological properties of selected ceramic coatings

The paper presents the characteristics of some ceramic coatings obtained by a plasma spray method. The ceramic coatings Al₂O₃, Cr₂O₃ and Cr₂O₃?+?5% TiO₂ were evaluated. Also the influence of the NiCr interlayer on the functional properties of sprayed coatings was studied. Other parameters studied included: thickness; microhardness; adhesion of the coatings; resistance to abrasive wear and thermal cyclic loading. The addition of TiO₂ to the Cr₂O₃ material increased the coating density, but did not substantially reduce the hardness. On the other hand, the lowest loss of material thickness was seen for Cr₂O₃; while the Al₂O₃ and the Cr₂O₃?+?5 wt.% TiO₂ material showed a higher loss. The loss in the case of the latter two was about the same. Relatively, higher values of abrasive wear resistance were observed in the Cr₂O₃ coatings, as compared to the reference material (Al₂O₃ coating), and the highest microhardness values were measured in the Cr₂O₃ coating. Finally, the metal interlayers in all coatings increased their resistance to thermal shock. All the coatings, using the interlayer to reduce differences in coefficients of thermal expansion, were suitable for the purpose of the thermal loading up to 1000?°C.     

Effects of Bi2O3-Nb2O5 additives on microstructure and magnetic properties of low-temperature-fired NiCuZn ferrite ceramics

NiCuZn ferrite with superior magnetic performance is vital ceramic material in multilayer chip inductors (MLCI) applications. In this study, low-temperature-sintered Ni_0.22Cu_0.2Zn_0.58Fe₂O₄ ferrite ceramic doped with 1.0?wt% Bi₂O₃-x?wt% Nb₂O₅ (where x?=?0.0, 0.1, 0.2, 0.3, 0.4 and 0.5) was synthesized via solid-state reaction method. Effects of Bi₂O₃-Nb₂O₅ additives on microstructures and magnetic properties of NiCuZn ferrite ceramics sintered at 900?°C were systematically investigated. Results indicate that an appropriate amount of Bi₂O₃-Nb₂O₅ composite additives can significantly promote grain growth and densification of NiCuZn ferrite ceramics when sintered at low temperatures. Specifically, samples doped with 1.0?wt% Bi₂O₃ and 0.4?wt% Nb₂O₅ additives exhibited excellent initial permeability (~ 410 @ 1?MHz), high cutoff frequency (~ 10?MHz), high saturation magnetization (~ 54.92?emu/g), and low coercive force (~ 20.32?Oe). These observations indicate that NiCuZn ferrite ceramics doped with appropriate amounts of Bi₂O₃-Nb₂O₅ additives are great candidate materials for MLCI applications.     

Mechanical and tribological properties of nano/micro composite alumina coatings fabricated by atmospheric plasma spraying

Adding nano particles can significantly improve the mechanical properties and wear resistance of thermal sprayed Al₂O₃ coating. However, it still remains a challenge to uniformly incorporate nano particles into traditional coatings due to their bad dispersibility. In the present work, nanometer Al₂O₃ (n-Al₂O₃) powders modified by KH-560 silane coupling agent were introduced into micrometer Al₂O₃ (m-Al₂O₃) powders by ultrasonic dispersion to afford nano/micro composite feedstock, and then four resultant coatings (weight fraction of n-Al₂O₃: 0%, 3%, 5% and 10%) were fabricated by atmospheric plasma spraying. The features and constitutes of feedstock and as-sprayed coatings, as well as their porosity, bonding strength, microhardness and frictional behaviors were investigated in detail. Results show that the nano/micro composite feedstock with uniform microstructure can be better melted in the spraying process, thereby obtaining coatings with denser microstructure, higher hardness and bonding strength. Added n-Al₂O₃ has no obvious effect on the friction coefficient of composite coatings, whereas can improve their wear-resistant and reduce the worn degree of counterpart. The wear mechanism of traditional coating is brittle fracture and lamellar peeling, while that of composite coating with weight fraction of n-Al₂O₃ of 10% is adhesive wear.     

Visible light induced photocatalytic activity of Nb2O5/carbon cluster/Cr2O3 composite materials

Nano-sized Nb₂O₅/carbon cluster/Cr₂O₃ composite material was prepared by the calcination of NbCl₅/chromium acetylacetonate/epoxy resin complex under an argon atmosphere. The Pt-loaded Nb₂O₅/carbon cluster/Cr₂O₃ composite material shows the photocatalytic activity under visible light irradiation. The composite material successfully decomposed the water into H₂ and O₂ in the [H₂]/[O₂] ratio of 2. Electron spin resonance spectral examination suggests a two-step electron transfer in the process of Nb₂O₅ → carbon cluster → Cr₂O₃ → Pt.     

Tribological properties of Al2O3 nanoparticles as lubricating oil additives

Nano-scale Al₂O₃ spherical particles, prepared via a hydrothermal method and modified by silane coupling agent, can be well-dispersed in lubricating oil. The tribology properties of Al₂O₃ nanoparticles as lubricating oil additives have been studied by four-ball and thrust-ring friction test, which illustrate that the modified Al₂O₃ nanoparticles can effectively improve the lubricating behaviors compared to the base oil. When the added concentration is 0.1 wt%, the friction coefficient and the wear scar diameter are both smallest. The lubrication mechanism is that a self-laminating protective film is formed on the friction surface and the wear behavior changes from sliding friction to rolling friction.     

Influence of Y2O3 on the microstructure and tribological properties of Ti-based wear-resistant laser-clad layers on TC4 alloy

Multi-track Ti-based wear-resistant composite coatings were fabricated on TC4 alloy surfaces using laser-clad TC4 + Ni45 + Co–WC mixed powders with different Y₂O₃ contents (0, 1, and 3 wt%). The microstructure, microhardness, and tribological properties of the coatings were characterised using X-ray diffraction, scanning electron microscopy, energy dispersive spectrometry, electron probe X-ray micro analyser, microhardness tester, and friction and wear testing apparatus. The results showed that the number of cracks on the coating surfaces gradually decreased with the addition of Y₂O₃ and that residual Co–WC powders existed in the coating subsurfaces. The phase composition of the coatings with different Y₂O₃ contents remained unchanged and was mainly composed of reinforcing phases of TiC, TiB₂, Ti₂Ni, and matrix α-Ti. With the addition of Y₂O₃, the coating microstructure was remarkably refined, the direction characteristic of the TiC dendrites obviously weakened, and the nucleation rate significantly increased. When the added Y₂O₃ was 3 wt%, a large amount of TiB₂–TiC-dependent growth composite phases precipitated in the coating. The two-dimensional lattice misfit between (0001)_TiB2 and (111)_TiC was 0.912%, which indicated that TiB₂ and TiC formed a coherent interface. When the amount of Y₂O₃ was increased, the microhardness of the coatings gradually decreased, and the wear volume of the coatings first increased and then decreased. Under the effect of the TiB₂–TiC composite phases, the wear resistance of the 3 wt% Y₂O₃ coating was optimal. The 3 wt% Y₂O₃ coating friction coefficient was the lowest, and the wear mechanism was abrasive wear.     

Wear-resistant ceramic coatings deposited by liquid thermal spraying

As a surface strengthening and surface modification technology of materials, liquid thermal spray technology has been used in many fields, such as wear and friction reduction, corrosion resistance, and high-temperature oxidation resistance. This article reviews the progress of liquid thermal sprayed coating in wear resistance as well as friction reduction in recent years. The influences of microstructure, composition, phase structure and mechanical properties on the tribological properties of typical coatings (including ceramic coatings and multiphase composite coatings) are investigated. The tribological properties of the coating are determined by the coating characteristics (including microstructure, porosity, mechanical properties, etc.) and the service conditions (working temperature, lubrication state, etc.). Typical ceramic wear-resistant coatings include Al₂O₃, YSZ, HA coatings, etc. The tribological properties of the coating can be significantly improved through process optimization and heat treatment. The comparison of nanostructured and microstructured ceramic-based coating reveals that nanostructured coating reduces wear by absorbing stress. The interaction between different constituent phases improves wear resistance and reduces wear in composite coatings. Finally, various challenges faced by liquid thermal spray are pointed out, and future research focuses are proposed.     

Friction and wear behavior of PTFE composites filled with rare earth compounds under oil‐lubricated conditions

Polytetrafluoroethylene (PTFE)‐based composites, filled with CeO₂, CeF₃, and La₂O₃ in volume contents of 5, 10, 15, 20, and 30%, were prepared. Then, the friction and wear behavior of these PTFE composites sliding against GCr15 bearing steel under both dry and liquid paraffin‐lubricated conditions was evaluated using an MHK‐500 ring‐on‐block wear tester. Finally, the worn surfaces and the transfer films of these PTFE composites were investigated using a scanning electron microscope (SEM) and an optical microscope. Experimental results showed that filling CeO₂, CeF₃, and La₂O₃ into PTFE can reduce the wear of the PTFE composites by 1–2 orders of magnitude. When the content of CeO₂ in PTFE is 15%, the friction and wear properties of the CeO₂‐filled PTFE composite are the best. Meanwhile, when the content of La₂O₃ in PTFE is between 15 and 20%, the PTFE composite filled with La₂O₃ exhibits excellent friction and wear‐reducing properties. However, the friction coefficient of the CeF₃‐filled PTFE composite increases but its wear decreases with increase in the content of CeF₃ from 5 to 30%. The friction and wear‐reducing properties of CeO₂‐, CeF₃‐, and La₂O₃‐filled PTFE composites can be greatly improved by lubrication with liquid paraffin, but the limit loads of the PTFE composites decrease with increase in the content of CeO₂, CeF₃, and La₂O₃ in PTFE (from 5 to 30%) under the same conditions. Investigations of worn surfaces show that the interaction between liquid paraffin and the CeO₂‐, CeF₃‐, and La₂O₃‐filled PTFE composites, especially the absorption of liquid paraffin into the microdefects of the PTFE composites, creates some cracks on the worn surfaces of the PTFE composites and that the creation and development of the cracks reduces the mechanical strength and the load‐supporting capacity of the PTFE composites. However, with increase of the content of CeO₂, CeF₃, and La₂O₃ in the PTFE, the microdefects in the PTFE composites also increase, which would lead to increase in the number of the cracks on the worn surfaces of the PTFE composites under load and, so, in turn, lead to the reduction of the limit loads of the CeO₂‐, CeF₃‐, and La₂O₃‐filled PTFE composites under lubrication with liquid paraffin. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 78: 797–805, 1999     

Oxygen and chlorine evolution on RuO2 + TiO2 + CeO2 + Nb2O5 mixed oxide electrodes

A systematic investigation was conducted on the mechanism and electrocatalytic properties of O₂ and Cl₂ evolution on mixed oxide electrodes of nominal composition: Ti/[Ru_(0.3)Ti_(0.6)Ce_(0.1−x)]O₂[Nb₂O₅]_(x) (0 ≤ x ≤ 0.1). For the oxygen evolution, a 30 mV Tafel slope is obtained in the presence of CeO₂, while in its absence a 40 mV coefficient is observed. The intrinsic electrocatalytic activity is mainly due to electronic factors, as result of the synergism between Ru and Ce oxides. For chlorine evolution, the Tafel slope (30 mV) is independent on oxide composition. The best global electrocatalytic activity for ClER was observed in the absence of Nb₂O₅ additive. Variation of the voltammetric charge throughout the experiments confirms high CeO₂ content compositions are fragile, due mainly to the porosity caused by CeO₂ presence. On the other hand, Nb₂O₅ addition decreases considerably this instability.     

Fabrication and characterisation of Cr and Co doped Bi1.5Zn0.92Nb1.5O6.92 pyrochlores

Cr and Co doped Bi_1.5Zn_0.92Nb_1.5O_6.92 pyrochlore ceramics were produced by solid state mixing of oxides. Cr and Co were doped into the Nb and Nb-Zn sites considering the compositions of Bi_1.5Zn_0.92Nb_1.5−xCr_xO_6.92−x, (Bi_1.5Zn_0.46)(Zn_0.46−3x/6Nb_1.5−3x/5Cr_x)O_6.92−x/2 for Cr doping and Bi_1.5Zn_0.92Nb_1.5−3x/5Co_xO_6.92, (Bi_1.5Zn_0.46)(Zn_0.46−3x/6Nb_1.5−3x/5Co_x)O_6.92−x/2 for Co doping. The solubility limit of Cr in BZN was higher than that of Co and the solubility limit increased when doping was made both into Nb and Zn sites. The second phases appeared when x > 0.2 for Cr and x > 0.15 for Co doping into the Nb-Zn sites. Simultaneous Cr doping into the Nb- and Zn-sites of BZN pyrochlore gave higher dielectric constant than doping into the Nb-site of pyrochlore. However, Co doping into the Nb- and Zn-sites and only into the Nb-site of BZN gave identical dielectric results in the range of 202-218. The temperature coefficient of dielectric constant decreased with Cr doping and increased with Co doping.     

Cr2O3 nanoparticles: A promising candidate to improve the mechanical properties and corrosion resistance of Ni-Co alloy coatings

This study was aimed to assess the effects of reinforcement nanoparticles content, on the microstructural features, mechanical properties, and corrosion-related properties of Ni-Co-Cr₂O₃ nanocomposite coatings. Scanning electron microscope (SEM), energy dispersive X-ray spectrometer (EDS), and X-ray diffraction (XRD) analysis were employed in order to evaluate the microstructural features and chemical composition of the nanocomposites. Moreover, the microhardness tester and electrochemical impedance spectra (EIS) tests coupled with potentiodynamic polarization measurements were used to investigate the mechanical and corrosion-related properties, respectively. Results demonstrate that albeit the volume fraction of cobalt in coating, average particle size, Cr₂O₃ nanoparticle content in coating, and microstructural features are of prime significance in determining the mentioned properties of the nanocomposite coatings, Co content is more important. Actually, Cr₂O₃ nanoparticles serve as suitable nucleation sites for Co particles deposition throughout the microstructure. Thus, combined actions of Cr₂O₃ nanoparticles incorporation and their optimal content ensures the nucleation of high population of Co particles, which significantly contributes to the improvement in the properties. The Ni-Co-8.9 wt%Cr₂O₃ nanocomposite coating exhibits the superior mechanical and corrosion-related properties.     

Characterization of alumina–3 wt.% titania coating prepared by plasma spraying of nanostructured powders

Nanostructured and conventional alumina–3 wt.% titania coatings were deposited by air plasma spraying (APS). The microstructure and phase composition of the coatings were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Mechanical properties including hardness, adhesion strength, crack extension force (G_C) and sliding wear rate were measured. Equiaxed α-Al₂O₃ grains were observed in the nanostructured Al₂O₃–3 wt.% TiO₂ coating and the diameter of α-Al₂O₃ grains were about 150 to 700 nm in size. The microhardness of both kinds of coating was similar and about 820 HV_0.2. However, the adhesion strength and crack extension force of the nanostructured coating increased by 33 and 80%, respectively, as compared with those of the conventional coating. The wear rate of the nanostructured coating was lower than that of the conventional coating. The results were explained in terms of characteristics of the powders and microstructure of the coatings.     

Cathode plasma electrolytic deposition of Al2O3 coatings doped with SiC particles

Semiconductor particles doped Al₂O₃ coatings were prepared by cathode plasma electrolytic deposition in Al(NO₃)₃ electrolyte dispersed with SiC micro- and nano-particles (average particle sizes of 0.5–1.7?µm and 40?nm respectively). The effects of the concentrations and particle sizes of the SiC on the microstructures and tribological performances of the composite coatings were studied. In comparison with the case of dispersing with SiC microparticles, the dispersion of SiC nanoparticles in the coatings was more uniform. When the concentration of SiC nanoparticles was 5?g/L, the surface roughness of the composite coating was reduced by 63%, compared with that of the unmodified coating. Friction results demonstrated that the addition of 5?g/L SiC nanoparticles reduced the friction coefficient from 0.60 to 0.38 and decreased the wear volume under dry friction. The current density and bath voltage were measured to analyze the effects of SiC particles on the deposition process. The results showed that the SiC particles could alter the electrical behavior of the coatings during the deposition process, weaken the bombardment of the plasma, and improve the structures of the coatings.     

Improving the tribological properties of plasma sprayed NiAl–Bi2O3–Ag–Cr2O3 composite coatings by hot isostatic pressing

In this study, the hot isostatic pressing (HIP) process was adopted to enhance the tribological response of plasma-sprayed NiAl–Bi₂O₃–Ag–Cr₂O₃ coatings under different temperature conditions. The HIP process was performed at a temperature of 800 °C, under a pressure of 100 MPa using argon gas. When compared with as-sprayed NiAl–Bi₂O₃–Ag–Cr₂O₃ composite coatings, the results revealed that the post-HIP process greatly reduced the porosity to a sufficiently low level of 2.7%, and led to a significant transformation from the splat lamellar to composition homogeneity across the entire coating. As highlighted in the hot isostatically pressed (HIPed) coating, more NiBi intermetallic compounds emerged. The mechanical hardness and adhesive strength increased considerably by 15.9% and 22.7%, respectively. The HIPed coating exhibited improved running stability in friction when exposed to different temperatures. In particular, the wear resistance increased significantly by one level of magnitude at the temperature range of room temperature (25 °C) to 400 °C, compared to the as-sprayed composite coating. This was attributed to the presence of the NiBi intermetallic compound and structural restoration after the HIP process. A protective tribo-layer was always present under alternating temperature conditions, and this allowed for continuous inhibition of wear. The mechanical evolution of the tribo-layer was further determined to clarify its effect on the resulting tribological behavior of the HIPed NiAl–Bi₂O₃–Ag–Cr₂O₃ coatings.     

Thermal cycling behavior of nanostructured 8YSZ，SZ/8YSZ and 8CSZ/8YSZ thermal barrier coatings fabricated by atmospheric plasma spraying

The nanostructured single-ceramic-layer (SCL) 8YSZ thermal barrier coatings (TBCs), double-ceramic-layer (DCL) Sm₂Zr₂O₇ (SZ)/8YSZ and SZ doped with 8 wt% CeO₂ nanoscale particles (8CSZ)/8YSZ TBCs were fabricated by atmospheric plasma spraying (APS) on nickel-based superalloy substrates with NiCoCrAlY as the bond coating. The thermal cycling behavior of the three as-sprayed TBCs was investigated systematically at 1000 ℃ and 1200 ℃. The results reveal that the thermal cycling lifetime of the nanostructured DCL 8CSZ/8YSZ TBCs is the longest among them, which is largely due to the fact that the intermediate layer buffer effect of the DCL structure, more porosity and improvement of thermal expansion coefficient from doping CeO₂ nanoparticles can relieve thermal stress to a great extent at elevated temperature. The failure mechanism of the nanostructured TBCs has been discussed in detail.