Yttria-Stabilized Zirconia Thermal Barriers Sprayed Using N<Subscript>2</Subscript>-H<Subscript>2</Subscript> and Ar-H<Subscript>2</Subscript> Plasmas: Influence of Processing and Heat Treatment on Coating Properties

Thermal barrier coatings were produced using both Ar and N₂ as the primary plasma gas. Various aspects of the process and the coatings were investigated. It was found that higher in-flight particle temperatures could be produced using N₂, but particle velocities were lower. Deposition efficiencies could be increased by a factor of two by using N₂ as compared to Ar. Coatings having similar values of porosity, hardness, Young’s modulus, and thermal diffusivity could be produced using the two primary gases. The coatings exhibited similar changes (increased hardness, stiffness, and thermal diffusivity) when heat-treated at 1400 °C. However, the N₂-processed coatings tended to have lower values of Young’s modulus and thermal diffusivity following such treatment. The results point to the potential advantage, in terms of reduced powder consumption and increased production rate, of using N₂ as compared to Ar as the primary plasma gas for TBC deposition. This article is an invited paper selected from presentations at the 2007 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Global Coating Solutions, Proceedings of the 2007 International Thermal Spray Conference, Beijing, China, May 14-16, 2007, Basil R. Marple, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2007.     

Thermoelectric properties of n-type Bi<Subscript>2</Subscript>Te<Subscript>2.7</Subscript>Se<Subscript>0.3</Subscript> compounds prepared by spark plasma sintering

In this study, the thermoelectric properties of 0.1 wt.% Cdl₂-doped n-type Bi₂Te_2.7Sb_0.3 compounds, fabrieated by SPS in a temperature range of 250°C to 350°C, were characterized. The density of the compounds was increased to approximately 100% of the theoretical density by carrying out consolidation at 350°C. The Seebeck coefficient, thermal conductivity, and electrical resistivity were dependent on a hydrogen reduction process and the sintering temperature. The Seebeck coefficient and the electrical resistivity increased with the reduction process. Also, electrical resistivity decreased and thermal conductivity increased with sintering temperature. The results suggest that carrier density and mobility vary according to the reduction process and sintering temperature. The highest figure of merit, 1.93×10⁻³ K⁻¹, was obtained for the compound consolidated at 350°C for 2 min.     

Processing and Mechanical Properties of Natural Rubber-ZnFe<Subscript>2</Subscript>O<Subscript>4</Subscript> Nanocomposites

We present preliminary results concerning natural rubber reinforced with nanometric ZnFe₂O₄ obtained from an industrial solid waste. The study investigate the influence of these nanometric ceramic particles on the processing as well as the mechanical properties of the obtained rubber composite, opening the possibility of partial replacement of carbon black and exposing a new potential composite material. The hardness of unfilled and reinforced rubber increased as nanometric ZnFe₂O₄ was increased. Besides, tensile properties of the reinforced rubber were measured, observing once again that as the amount of nanometric ZnFe₂O₄ particles was increased, ultimate strength improved from 2.5 MPa to almost 20 MPa.     

Preparation and optical properties of Y<Subscript>2</Subscript>O<Subscript>3</Subscript>/SiO<Subscript>2</Subscript> powder

Y(NO3)3 and NH3·H2O were used as a raw materials,and nano-Y2O3 powder was successfully synthesized by a precipitation method.Employing TEOS as a raw material,SiO2 powder was successfully prepared by a alkoxide-hydrolysis method,and a Y2O3/SiO2 composite powder was obtained by coating.The Y2O3,SiO2,and Y2O3/SiO2 powders were characterized using X-ray diffraction(XRD),scanning electron microscopy(SEM),and Fourier transform infrared spectrophotometer(FT-IR);the Y2O3 and Y2O3/SiO2 powders were further examined ...     

Effects of nano-TiO<Subscript>2</Subscript> dispersion on thermoelectric properties of Co<Subscript>4</Subscript>Sb<Subscript>11.7</Subscript>Te<Subscript>0.3</Subscript> composites

Nano-TiO2/Co4Sb11.7Te0.3 composites were prepared by mechanical alloying (MA) and cold isostatic pressing (CIP) process.The phase composition,microstructure,and thermoelectric properties were characterized.The diffraction spectra of all samples well corresponds to CoSb3 skutterudite diffraction plane.TiO2 agglomerates into irregular clusters.They locate at the grain boundaries or some are distributed on the surface of Co4Sb11.7Te0.3 particles.For composites with high TiO2 content (0.6% and 1.0% TiO2),the phonon scattering by TiO2 particle,pores,and small size grains can result in a remarkable reduction in thermal conductivity.The maximum value of ZT is 0.79 for sample with 0.6 wt.% TiO2 at 700 K,which is 11% higher than that of non-dispersed sample.     

Microstructure and microwave dielectric properties of ZnO-B2O3 added （Ca0.254Li0.19Sm0.14）TiO3 ceramics

The effects of ZnO-B2O3 (ZB2) on the sintering behavior and microwave dielectric properties of (Ca0.254Li0.19Sm0.14)TiO3 ceramics were investigated.The densities of the specimens reached the maximum value by adding 3 wt.% ZB2 and then decreased.The sintering temperature of the specimens was lowered from 1300 to 1100°C without degradation of the microwave dielectric properties.The (Ca0.254Li0.19Sm0.14)TiO3 + 3 wt.% ZB2 sintered at 1100°C for 3 h showed good microwave dielectric properties,εr = 108.2,Qf = 6545 GHz,and τf = 6.5 ppm/°C,respectively,indicating that ZB2 was an effective sintering aid to improve the densification and microwave dielectric properties of (Ca0.254Li0.19Sm0.14)TiO3 ceramics.     

Superior performance of high-velocity oxyfuel-sprayed nanostructured TiO<Subscript>2</Subscript> in comparison to air plasma-sprayed conventional Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-13TiO<Subscript>2</Subscript>

Air plasma-sprayed conventional alumina-titania (Al₂O₃-13wt.%TiO₂) coatings have been used for many years in the thermal spray industry for antiwear applications, mainly in the paper, printing, and textile industries. This work proposes an alternative to the traditional air plasma spraying of conventional aluminatitania by high-velocity oxyfuel (HVOF) spraying of nanostructured titania (TiO₂). The microstructure, porosity, hardness (HV 300 g), crack propagation resistance, abrasion behavior (ASTM G65), and wear scar characteristics of these two types of coatings were analyzed and compared. The HVOF-sprayed nanostructured titania coating is nearly pore-free and exhibits higher wear resistance when compared with the air plasma-sprayed conventional alumina-titania coating. The nanozones in the nanostructured coating act as crack arresters, enhancing its toughness. By comparing the wear scar of both coatings (via SEM, stereoscope microscopy, and roughness measurements), it is observed that the wear scar of the HVOF-sprayed nanostructured titania is very smooth, indicating plastic deformation characteristics, whereas the wear scar of the air plasma-sprayed alumina-titania coating is very rough and fractured. This is considered to be an indication of a superior machinability of the nanostructured coating.     

Preparation of TiO<Subscript>2</Subscript> Nanopowders by Plasma Spray and Characterizations

TiO₂ powders with the range of 10-60 nm were prepared successfully by plasma spray in the self-developed plasma spray equipment. The prepared nanopowders were characterized by transmission electron microscopy, X-ray diffraction, and X-ray photoelectron spectroscopy. The results showed that the prepared TiO₂ nanopowders were the mixture of anatase phase and rutile phase, the main phase was anatase. There were O, Ti, and C elements in powders; Ti element still existed in tetravalent. The photocatalytic degradation of methyl orange indicated that all methyl orange (20 mg/L) can be degraded fully when the addition of prepared TiO₂ nanopowders and illumination time were 1 g/L and 150 min, respectively.     

Effects of silver powder particle size on the microstructure and properties of Ag-Yb<Subscript>2</Subscript>O<Subscript>3</Subscript> electrical contact materials prepared by spark plasma sintering

Ag-Yb₂O₃ electrical contact materials were fabricated by spark plasma sintering (SPS). The effects of silver powder particle size on the microstructure and properties of the samples were investigated. The surface morphologies of the sintered samples were examined by optical microscope (OM), and the fracture morphologies were observed by scanning electron microscopy (SEM). The physical and mechanical properties such as density, electrical resistivity, microhardness, and tensile strength were also tested. The results show that the silver powder particle size has evident effects on the sintered materials. Comparing with coarse silver powder (5 μm), homogeneous and fine microstructure was obtained by fine silver powder (≤0.5 μm). At the same time, the electrical conductivity, microhardness, and tensile strength of the sintered samples with fine silver powder were higher than those of the samples with coarse silver powder. However, silver powder particle size has little influence on the relative densities, which of all samples (both by fine and coarse silver powders) is more than 95%. The fracture characteristics are ductile.     

HVOF-Sprayed Coatings Engineered from Mixtures of Nanostructured and Submicron Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-TiO<Subscript>2</Subscript> Powders: An Enhanced Wear Performance

In previous studies, it has been demonstrated that nanostructured Al₂O₃-13 wt.%TiO₂ coatings deposited via air plasma spray (APS) exhibit higher wear resistance when compared to that of conventional coatings. This study aimed to verify if high-velocity oxy-fuel (HVOF)-sprayed Al₂O₃-13 wt.%TiO₂ coatings produced using hybrid (nano + submicron) powders could improve even further the already recognized good wear properties of the APS nanostructured coatings. According to the abrasion test results (ASTM G 64), there was an improvement in wear performance by a factor of 8 for the HVOF-sprayed hybrid coating as compared to the best performing APS conventional coating. When comparing both hybrid and conventional HVOF-sprayed coatings, there was an improvement in wear performance by a factor of 4 when using the hybrid material. The results show a significant antiwear improvement provided by the hybrid material. Scanning electron microscopy (SEM) at low/high magnifications showed the distinctive microstructure of the HVOF-sprayed hybrid coating, which helps to explain its excellent wear performance. This article is an invited paper selected from presentations at the 2007 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Global Coating Solutions, Proceedings of the 2007 International Thermal Spray Conference, Beijing, China, May 14-16, 2007, Basil R. Marple, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2007.     

Fabrication and Properties of Plasma-Sprayed Al<Subscript>2</Subscript>O<Subscript>3</Subscript>/ZrO<Subscript>2</Subscript> Composite Coatings

Al₂O₃ /xZrO₂ (where x = 0, 3, 13, and 20 wt.%) composite coatings were deposited onto mild steel substrates by atmospheric plasma spraying of mixed α-Al₂O₃ and nano-sized monoclinic-ZrO₂ powders. Microstructural investigation showed that the coatings comprised well-separated Al₂O₃ and ZrO₂ lamellae, pores, and partially molten particles. The coating comprised mainly of metastable γ-Al₂O₃ and tetragonal-ZrO₂ with trace of original α-Al₂O₃ and monoclinic-ZrO₂ phases. The effect of ZrO₂ addition on the properties of coatings were investigated in terms of microhardness, fracture toughness, and wear behavior. It was found that ZrO₂ improved the fracture toughness, reduced friction coefficient, and wear rate of the coatings.     

Preparation and characterization of nanostructured Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-13wt.%TiO<Subscript>2</Subscript> ceramic coatings by plasma spraying

Nanostructured and conventional Al₂O₃-13wt.%TiO₂ ceramic coatings were prepared by plasma spraying with nanostructured agglomerated and conventional powders, respectively. The microstructure and microhardness of the coatings were investigated using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and microhardness measurement. Meanwhile, the friction and wear behaviors were analyzed and compared using a ball-on-disk tribometer. The results show that the conventional coating has lamellar stacking characteristic and has some pores. However, the nanostructured coating shows a bimodal microstructure, which is composed of both fully melted regions and partially melted regions. According to the microstructural difference, the partially melted regions can be divided into liquid-phase sintered regions (a three-dimensional net or skeleton-like structure: Al₂O₃-rich submicron particles embedded in the TiO₂-rich matrix) and solid-phase sintered regions (remained nanoparticles). The microstructural characteristics of the liquid-phase sintered region are formed due to the selective melting of TiO₂ nanoparticles during plasma spraying. On the other hand, the TiO₂ and Al₂O₃ nanoparticles of the solid-phase sintered regions are all unmelted during plasma spraying. Due to the existence of nanostructured microstructures, the nanostructured coating has a higher microhardness, a lower friction coefficient, and a better wear resistance than the conventional coating.     

Influences of NiCO<Subscript>3</Subscript> content on the microstructure and magnetic properties of Ni<Subscript>0.5</Subscript>Zn<Subscript>0.5</Subscript>Fe<Subscript>2</Subscript>O<Subscript>4</Subscript> powders prepared by SHS

Stoichiometric Ni_0.5Zn_0.5Fe₂O₄ powders were produced by self-propagating high temperature synthesis (SHS). The effects of NiCO₃ content in the raw materials on the microstructure and magnetic properties of Ni-Zn ferrite powders were systematically studied. The Ni_0.5Zn_0.5Fe₂O₄ powders were characterized by X-ray diffraction (XRD) and scanning electron microscopy (SEM). The magnetic properties of the powders were evaluated by vibrating sample magnetometry (VSM). The results show that the introduction of NiCO₃ into reactants improves the conversion percentage and refines the Ni_0.5Zn_0.5Fe₂O₄ particles. The increase of NiCO₃ content enhances the magnetic properties of Ni_0.5Zn_0.5Fe₂O₄. Particularly, the saturation magnetization reaches the maximum when the NiCO₃ content is 3 at.%.     

Electrochemical behavior of zirconium in molten NaCl-KCl-K<Subscript>2</Subscript>ZrF<Subscript>6</Subscript> system

The electrochemical reduction of Zr4+(complex) ions in NaCl-KCl-K2ZrF6 molten salt on Pt electrode was investigated using cyclic voltammetry and square wave voltammetry at 1023 K.Two cathodic reduction peaks related to Zr4+/Zr2+ and Zr2+/Zr steps were observed in the cyclic voltammograms.The result was also confirmed by square wave voltammetry.The diffusion coefficient of Zr4+(complex) ions at 1023 K in NaCl-KCl-K2ZrF6 melt,measured by cyclic voltammetry,is about 4.22×10-6 cm2/s.The characterization of the deposits obtained by potentiostatic electrolysis at different potentials was investigated by XRD,and the results were well consistent with the electrochemical reduction mechanism of Zr4+(complex) ions.     

Synthesis and electrochemical performance of YF<Subscript>3</Subscript>-coated LiMn<Subscript>2</Subscript>O<Subscript>4</Subscript> cathode materials for Li-ion batteries

Spinel LiMn₂O₄ cathodes were coated with 1 mol% YF₃. X-ray diffraction (XRD) analyses showed that Y and/or F did not enter the lattice of the LiMn₂O₄ crystal. Transmission electron microscopy (TEM) showed that a compact YF₃ layer of 5–20 nm in thickness was coated onto the surface of LiMn₂O₄ particles. Scanning electron microscopy (SEM) observation showed that the YF₃ coating caused the agglomeration of LiMn₂O₄ particles. The cycling test demonstrated that the YF₃ coating can improve the electrochemical performance of LiMn₂O₄ at both 20 and 55°C. Moreover, YF₃-coated LiMn₂O₄ exhibited an improved rate capability compared with the uncoated one at high rates over 5C. The immersion test in electrolytes showed that YF₃-coated LiMn₂O₄ is more erosion resistant than the uncoated one.     

Photoresponse and donor concentration of plasma-sprayed TiO<Subscript>2</Subscript> and TiO<Subscript>2</Subscript>-ZnO electrodes

The photoelectrochemical characteristics of plasma-sprayed porous TiO₂, TiO₂-5%ZnO, and TiO₂-10%ZnO electrodes in 0.1 N NaOH solution were studied through a three-electrode cell system. The microstructure, morphology, and composition of the electrodes were analyzed using an electron probe surface roughness analyzer (ERA-8800FE), scanning electron microscopy, and x-ray diffraction. The results indicate that the sprayed electrodes have a porous microstructure, which is affected by the plasma spray parameters and composition of the powders. The TiO₂-ZnO electrodes consist of anatase TiO₂, rutile TiO₂, and Zn₂Ti₃O₈ phase. The photoresponse characteristics of the plasma-sprayed electrodes are comparable to those of single-crystal TiO₂, but the breakdown voltage is close to 0.5 V (versus that of a saturated calomel electrode). The short-circuit photocurrent density (J _SC) increases with a decrease of donor concentration, which was calculated according to the Gartner-Butler model. For the lowest donor concentration of a TiO₂-5%ZnO electrode sprayed under an arc current of 600 A, the short-circuit J _SC is approximately 0.4 mA/cm² higher than that of the TiO₂ electrodes under 30 mW/cm² xenon light irradiation. The J _SC increases linearly with light intensity. The original version of this paper was published as part of the DVS Proceedings: “Thermal Spray Solutions: Advances in Technology and Application,” International Thermal Spray Conference, Osaka, Japan, 10–12 May 2004, CD-Rom, DVS-Verlag GmbH, Düsseldorf, Germany.     

Fabrication and magnetic properties of NiFe<Subscript>2</Subscript>O<Subscript>4</Subscript> nanorods

NiFe₂O₄ nanorods have been successfully synthesized via thermal treatment of the rod-like precursor fabricated by Ni-doped α-FeOOH, which was enwrapped by the complex of citric acid and Ni²⁺. The morphology evolution during the calcination of the precursor nanorods was investigated with transmission electron microscopy (TEM), and the phase and the magnetic properties of samples were analyzed through X-ray diffraction (XRD) and vibrating sample magnetometer (VSM). The results indicated that the diameter of the NiFe₂O₄ nanorods obtained ranged between 30 and 50 nm, and the length ranged between 2 and 3 μm. As the calcination temperature was up to 600°C, the coercivity, saturation magnetization, and remanent magnetization of the samples were 36.1 kA·m⁻¹, 27.2 A·m²·kg⁻¹, and 5.3 A·m²·kg⁻¹, respectively. The NiFe₂O₄ nanorods prepared have higher shape anisotropy and superior magnetic properties than those with irregular shapes.     

Solvothermal synthesis and thermoelectric properties of skutterudite compound Fe（0.25）Ni（0.25）Co（0.5）Sb3

Nanostructured skutterudite-related compound Fe_0.25Ni_0.25Co_0.5Sb₃ was synthesized by a solvothermal method using FeCl₃, NiCl₂, CoCl₂, and SbCl₃ as the precursors and NaBH₄ as the reductant. The solvothermally synthesized powders consisted of fine granules with an average particle size of tens of nanometers. The bulk material was prepared by hot pressing the powders. Transport property measurements indicated a heavily doped semiconductor behavior with n-type conduction. The thermal conductivity is about 1.83 W·m⁻¹·K⁻¹ at room temperature and decreases to 1.57 W·m⁻¹·K⁻¹ at 673 K. The low thermal conductivity is attributed to small grain size and high porosity. A maximum dimensionless figure of merit of 0.15 is obtained at 673 K.     

Mechanical Properties of Layered La<Subscript>2</Subscript>Zr<Subscript>2</Subscript>O<Subscript>7</Subscript> Thermal Barrier Coatings

Lanthanum zirconate (La₂Zr₂O₇) has been proposed as a promising thermal barrier coating (TBC) material due to its low thermal conductivity and high stability at high temperatures. In this work, both single and double-ceramic-layer (DCL) TBC systems of La₂Zr₂O₇ and 8 wt.% yttria-stabilized zirconia (8YSZ) were prepared using air plasma spray (APS) technique. The thermomechanical properties and microstructure were investigated. Thermal gradient mechanical fatigue (TGMF) tests were applied to investigate the thermal cycling performance. The results showed that DCL La₂Zr₂O₇ + 8YSZ TBC samples lasted fewer cycles compared with single-layered 8YSZ TBC samples in TGMF tests. This is because DCL La₂Zr₂O₇ TBC samples had higher residual stress during the thermal cycling process, and their fracture toughness was lower than that of 8YSZ. Bond strength test results showed that 8YSZ TBC samples had higher bond strength compared with La₂Zr₂O₇. The erosion rate of La₂Zr₂O₇ TBC samples was higher than that of 8YSZ samples, due to the lower critical erodent velocity and fracture toughness of La₂Zr₂O₇. DCL porous 8YSZ + La₂Zr₂O₇ had a lower erosion rate than other SCL and DCL La₂Zr₂O₇ coatings, suggesting that porous 8YSZ serves as a stress-relief buffer layer.