Development of YBCO coatings by atmospheric plasma spraying

Superconducting Y–Ba–Cu–O thick films were produced by the atmospheric plasma spraying method. The effect of processing parameters (powder characteristics, spraying parameters) on the coatings properties was studied. X-ray diffraction analysis, SEM studies combined with EDS microanalysis and scratch test experiments were carried out in order to characterize the adhesion of the coatings to the substrate, the coatings morphology the thickness and crystalline structure as well as the powder phase transformations during spraying. For restoring the superconducting phase after deposition, the coatings were heated in oxygen in the temperature range 750–930°C. It was shown that the quality of the coatings and the adhesion to the substrate are greatly dependent on the deposition conditions. By calcining in oxygen under the appropriate conditions coatings consisting of the pure superconducting phase can be obtained.     

High-temperature performances of Si-HfO2-based environmental barrier coatings via atmospheric plasma spraying

To improve high-temperature bearing capability of coatings, novel agglomerated Si-HfO₂ powders were prepared by adding HfO₂ powders into original Si powders by spray drying method. Three-layer environmental barrier coatings (EBCs) with Si-HfO₂ bond layer, Yb₂Si₂O₇ intermediate layer and Yb₂SiO₅ surface layer were prepared on SiC ceramic substrates by atmospheric plasma spraying (APS). The high temperature properties of coatings were systematically investigated. The results indicated that the coatings had good high temperature oxidation resistance, and remained intact after being oxidized or steam corrosion at 1400 °C for 500 h, so the addition of HfO₂ improved the thermal cycling performances of the coating. The HfO₂ in Si bond coating could effectively inhibit the growth of thermal grown oxide at high temperatures. This work indicates that the high temperature properties of the coatings are improved by this novel EBCs using the novel agglomerated Si-HfO₂ powders.     

Laser stealth and laser protection properties of oxide-carbide coatings prepared by atmospheric plasma spraying

With the development of laser technology, laser-related materials have been widely studied. Both laser stealth coatings and laser protective coatings are currently the focus of attention. However, less research has been done on laser stealth and protective integrated coatings. In this paper, plasma-sprayed Y₂O₃–Ti₃AlC₂ coatings were prepared with low-power (LP) and high-power (HP) parameters, and their laser stealth and laser protection properties were characterized. The LP coating and HP coating appeared to have lower reflectivity at 1064 nm because a low-reflectivity second phase and many loose flocs on the surface are introduced, which indicates excellent laser stealth performance. When irradiated by a laser, the LP coating exhibited excellent laser protection ability, and its reflectivity increased after irradiation because Ti₃AlC₂ oxidized and decomposed and densely arranged small particles formed on the surface. The LP coating perfectly protected the 500-W laser irradiation for 20 s. In addition, the laser damage threshold of the LP coating was 5.599 s at 1000-W laser irradiation, which indicates that the LP Y₂O₃–Ti₃AlC₂ coating is a potential material with laser stealth and laser protection integration.     

Fabrication and characterization of 8YSZ ceramic based abradable seal coatings by atmospheric plasma spraying

8 wt% yttria-stabilized zirconia (8YSZ) powders are fabricated as high-temperature based materials via a solid-state reaction method and ground into spheres in this paper. Following that, 4 wt% Nickle (Ni), 4 wt% Hexagonal Boron Nitride (hBN) and 4 wt% PHB (Polyphenyl ester) are added to 8YSZ for getting 8YSZ ceramic-based abradable seal powders (8YSZ CAS_p). Then, the 8YSZ CAS_p are sprayed on the stainless steel substrate with a NiCoCrAlY transition layer by an atmospheric plasma spraying (APS) technology. The phase structure, surface morphology and the cross-section topography of the fabricated are analyzed, the indentation hardness and nano-indentation test are conducted. The experiments of 8YSZ ceramic-based abradable seal coatings (8YSZ CAS_c) show that the deposition efficiency and porosity are respectively 78.5% and 21.8%, the bond strength is 4.6 MPa, the cycle number of thermal shock resistance is 37 times, those parameters prove that the fabricated 8YSZ CAS_c are promising abradable seal coatings.     

Preparation of metallic coatings with reversibly switchable wettability based on plasma spraying technology

Plasma spray technology was used for the preparation of metallic coatings with reversibly switchable wettability. By spraying Fe, Cr, and Ni mixture powders with different sizes, a micro/submicro-dual scale morphology was obtained. The resultant metallic coating had a superhydrophilic nature, but could be switched into superhydrophobic by spraying an acetone solution of dodecanoic acid while the sprayed surface remained within a temperature range of 100?C200°C, although dodecanoic acid itself has a hydrophilic nature. The obtained superhydrophobic coating remained stable if the temperature was below 200°C. The surface wettability could further be switched between superhydrophilicity and superhydrophobicity within a time-scale of only seconds by heating above 220°C and re-spraying the acetone solution of dodecanoic acid in the temperature range of 100?C200°C. A chemisorbed molecular layer of dodecanoic acid was responsible for the decrease of the surface energy, and the Fourier transform infrared spectroscopy (FTIR) results suggested that heating the substrate can greatly facilitate the formation of the chemisorbed layer and preferential orientation of the dodecanoic acid molecule.     

Challenging zircon coatings by suspension plasma spraying

Zircon is a ceramic material that decomposes at high temperature, limiting its use by conventional thermal spraying. In this work, it is intended to use thermal spraying from concentrated aqueous suspensions to evaluate the possibility of obtaining coatings in which a significant proportion of zircon could be preserved. For this purpose, stable concentrated suspensions of zircon have been prepared, which have been subsequently sprayed at two different spraying distances. The coatings were characterised in terms of microstructural features and the amount of zircon present in the coatings was quantified. All the coatings obtained display the typical microstructure derived from the deposition of liquid feedstocks by plasma spraying. In all cases, the XRD analysis demonstrates the partial decomposition of zircon into zirconia and residual silica, but also that a significant percentage (about 20%) is preserved without decomposing, which marks a strong difference with respect to reported data for atmospheric plasma spraying.     

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.     

Preparation of high solids content nano-titania suspensions to obtain spray-dried nanostructured powders for atmospheric plasma spraying

Nanosized TiO₂ powder with an average primary size of ∼20 nm and surface area of ∼50 m²/g (Aeroxide^® P25, Degussa-Evonik, Germany) was used as starting material. A colloidal titania suspension from the same supplier was also used (W740X). The dispersing conditions were studied as a function of pH, dispersant content, and solids loading. Well-dispersed TiO₂ nanosuspensions with solids contents up to 30 vol.% (62 wt%) were obtained by dispersing the powder with 4 wt% PAA. Suspensions with solids contents as high as 35 vol.% were prepared by adding the TiO₂ nanoparticles to the TiO₂ colloidal suspension under optimised dispersing conditions.TiO₂ powder reconstitution was performed by spray drying both types of nanosuspensions to obtain free-flowing micrometre-sized nanostructured granules. The spray-dried nanostructured TiO₂ granules were deposited on austenitic stainless steel coupons using atmospheric plasma spraying. Coating microstructure and phase composition were characterised using scanning electron microscopy and X-ray diffraction techniques.     

Deposition and ablation resistance of HfC-based coatings prepared on SiC-coated C/C composites by supersonic atmospheric plasma spraying

In order to improve the ablation properties of C/C composites, HfC-based coatings with different mass ratios of SiC were deposited on the surface of SiC-coated carbon/carbon composites by supersonic atmospheric plasma spraying. The morphologies and microstructures of the HfC-based coatings were characterised. The ablation resistance test was carried out by oxyacetylene torch. The results show that the as-prepared coatings are multiphase coatings consisting of HfC, HfO₂, SiC and SiO₂. The structure of different coatings is dense. After ablation for 60?s, the ablation centre region of coating is smooth without obvious microcrack and pinhole, and no interlaminar crack can be observed at the cross-section. An Hf–Si–O compound oxide layer is generated on the surface of coating, which is beneficial for protecting the C/C composites from being ablated. Meanwhile, the further generated HfSiO₄ can play a pinning effect, which can prevent crack extension.     

Reel-to-reel inline atmospheric plasma deposition of hydrophobic coatings

Plasma deposition equipment was developed and installed at a pilot extrusion coating line for reel-to-reel substrates. Hexamethyldisiloxane was used as a siloxane precursor for the atmospheric plasma deposition of siloxane coatings on substrates of three different categories: paper, polyethylene-coated paper, and textile materials (woven cotton fabric and polypropylene nonwoven). SEM, H₂O contact angle measurements, heat sealability, and water vapor barrier measurements were carried out to characterize the composition and surface structure of the samples. The potential of the method and the equipment was shown by the coatings, ranging to micrometer scale. With selected samples, hydrophobic coating was shown to form at speeds up to 100 m/min.     

等离子喷涂Al2O3陶瓷涂层的研究

研究等离子喷涂Al2O3陶瓷涂层的抗热震性能,分析并计算等离子喷涂Al2O3陶瓷涂层和AlAl2O3涂层中的残余应力,得出了两种涂层的应力分布,测试了TiO2含量对Al2O3陶瓷涂层性能的影响,检验了影响涂层质量的工艺参数.     

The mechanism of the low-temperature formation of barium hexaferrite

We have investigated the formation of barium hexaferrite via the coprecipitation method. Fine precursor powders were obtained with coprecipitation from water and ethanol solutions of various reagent salts. The coprecipitates were calcined at 300–800 °C for 0–50 h. The samples were characterized with X-ray powder diffraction, thermal analysis, electron microscopy and magnetometry. The formation of barium hexaferrite was a combination of two competing mechanisms and was not influenced by the reagent salts or the solvent. The formation temperature of the barium hexaferrite was reduced to 500 °C by optimizing the coprecipitation conditions.     

Influence of SiC fiber on thermal cycling lifetime of SiC fibers /YSZ thermal barrier coatings by atmospheric plasma spraying

The initiation and propagation of cracks under thermal stresses easily is one of the problems limiting the thermal cycling lifetime of thermal barrier coatings (TBCs). In order to improve the thermal cycling lifetime, SiC fibers were introduced to yttria stabilized zirconia (YSZ) coating deposited on In738LC substrate by atmospheric plasma spray (APS). Phase composition, thermal cycling behaviors and fiber toughening mechanisms of coatings were systematically investigated by X-ray diffraction (XRD), scanning electron microscopy (SEM) and thermal cycling test. Results showed that the thermal cycling lifetime and fracture toughness of SiC fibers/YSZ coatings could reach 442?±?13 and 1.54?±?0.19?MPa $\sqrt{m}$ respectively, which were 1.6 times and 1.3 times higher than that of conventional TBCs. There are two stages of fiber reinforced during thermal cycling, and the first is crack deflection and termination, the second is fiber debonding, pull-out, breakage and bridging. Meanwhile, SiC fibers could prevent the stress-activated ZrO₂ martensitic transformation by reducing the stress in the lattice.     

Structure and mechanical properties of hydroxyapatite coatings produced on titanium using plasma spraying with induction preheating

Coatings of hydroxyapatite (HAp) were prepared by plasma spraying with induction preheating of titanium substrate from 200 to 1000 °C. The combination of conventional plasma spraying and induction preheating ensured high mechanical properties of HAp coatings. The coatings produced in the temperature range 400–600 °C were characterized by homogeneous nanostructure of splats with an average grain size of 12–31 nm. According to the results of nanoindentation HAp coatings with high hardness 0.9–1.2 GPa and elastic modulus 7–16 GPa were formed on the titanium.     

Dielectric properties of M-type barium hexaferrite prepared by co-precipitation

Highly stoichiometric and phase pure barium hexaferrite has been synthesized by co-precipitation as well as a solid-state preparative method using high purity nitrates, oxides and carbonates of iron(III), barium(II) and ammonium hydroxide. The isochronal and isothermally measured complex permittivity and dielectric loss tangents over 1 MHz–1 GHz in frequency remained relatively stable until a sintering temperature between 1100 and 1300 °C. A high value of relative permittivity of 32 and low loss tangent of 0.0329 indicate suitable high frequency characteristics for barium hexaferrite. The measured apparent densities before and after each firing cycle showed a monotonic increase. The crystal structure determined from X-ray diffraction studies confirmed the presence of single phase belonging to the theoretical space group P63/mmc with calculated cell parameters of a = b = 5.895 Å and c = 23.199 Å. In addition the DTA hexaferrite formation temperature was found to be 1050 °C.     

Oxidation kinetics of atmospheric plasma sprayed environmental barrier coatings

Three different Si/Yb-silicate environmental barrier coating systems (EBCs) were atmospheric plasma sprayed using various spray currents (275, 325, 375 A) for Yb-silicate deposition. The EBCs were thermally cycled between room temperature and 1300 °C up to 1000 h in air. Additionally, bare Si coatings were tested under isothermal and thermal cycling conditions in the as-sprayed state and after polishing at 1300 °C in air. Parabolic oxidation kinetics were observed and oxidation protection provided by Yb-silicate was found to be influenced by the spray conditions, i.e. only at 325 A, Yb-silicate was effectively protecting the bond coat. The controlling mechanism was attributed to densification in the Yb-silicate layer during thermal cycling, which was quantified via image analysis. The surface finish of the Si coating was also found to be influencing the oxidation rate. The TGO was thinner and less cracked on polished APS Si coating in comparison with the as-sprayed Si coating surface.