Effect of MgO sintering additive on mullite structures manufactured by fused deposition modeling (FDM) technology

An optimized recipe for 3D printing of Mullite-based structures was used to investigate the effect of MgO sintering additive on the processing stages and final ceramic properties. To achieve dense 3:2 mullite, ceramic filaments were prepared based on an alumina powder, a methyl silicone resin, EVA elastomeric binder and MgO powder. Using 1 wt% MgO and a dwell time of 5 h at 1600 °C, a dense mullite structure could be obtained from filaments with a diameter of 1.75 mm. Ceramic structures with and without sintering additive were printed in vertical and horizontal direction, to investigate the effect of printing direction on mechanical strength after sintering. Using four-point bending test, it was demonstrated that by using MgO, the printing orientation did not affect the mechanical strength significantly anymore. The low Weibull modulus could be explained by the closed porosity that emerge during the degassing of the preceramic polymer due to cross-linking.     

Indentation method for fracture resistance determination of metal/ceramic interfaces in thick TBCs

The indentation technique has been used to measure the adhesion of plasma- sprayed ceramic coatings on metals intended for thick thermal barrier coating ( TTBC) applications. This approach provides the adhesion value as the critical strain energy release rate,Gc, of the interface, which also takes into account any residual stresses. The theoretical background of the method is outlined, and specific examples are reported with respect to the effect of substrate temperature on the metal/ceramic adhesion of thick TBCs.     

Effect of ZrO<Subscript>2</Subscript> coating on<Emphasis Type="Italic">in vitro</Emphasis> formation of calcium phosphate

We prepared zirconia thin films on (100) Si wafer by using a chemical solution deposition with a zirconium naphthenate as a starting material. The films were pyrolyzed at 500°C for 10 min and finally annealed for 30 min in air at 500°C. Amorphous films after annealing had no distinct structure and were uniform along the cross section line.In vitro formation of the calcium phosphate was evaluated by the field emission-scanning electron microscope, energy dispersive X-ray spectrometer and Fourier transform infrared spectroscopy.     

Solar furnace surface treatment of plasma-sprayed thermal barrier coatings

An original process of superficial thermal treatment is described. This process has been successfully applied to partially stabilized yttria-zirconia coatings (ZrO₂-Y₂O₃) to increase the lifetime of the thermal barriers. A thin superficial layer was melted, and morphological transformations were observed. A microstructural comparison between as-sprayed layers and thermally treated layers is presented.     

Microstructures and Properties of Laser-Glazed Plasma-Sprayed ZrO2-YO1.5/Ni-22Cr-10AI-1Y Thermal Barrier Coatings

Thermal barrier coatings (TBCs) consisting of two layers with various yttria contents (ZrO ₂- YO_1.5/Ni-22Cr-10Al- lY) were plasma sprayed, and parts of the various specimens were glazed by using a pulsed CO₂ laser. All the specimens were then subjected to furnace thermal cycling tests at 1100 °C; the effect of laser glazing on the durability and failure mechanism of the TBCs was then evaluated. From these results, two models were developed to show the failure mechanism of as- sprayed and laser- glazed TBCs: model A, which is thermal-stress dominant, and model V, which is oxidation-stress dominant. For top coats containing cubic phase, cubic and monoclinic phases, or tetragonal and a relatively larger amount of monoclinic phases, whose degradation is thermal- stress dominant, laser glazing improved the durability of TBCs by a factor of about two to six. Segmented cracks that occurred during glazing proved beneficial for accommodating thermal stress and raising the tolerance to oxidation, which resulted in a higher durability. Thermal barrier coatings with top coats containing tetragonal phase had the highest durability. Degradation of such TBCs resulted mainly from oxidation of the bond coats. For top coats with a greater amount of monoclinic phase, thermal mismatch stress occurred during cooling and detrimentally affected durability.     

ZrO2基纳米催化吸收剂的制备及脱硫性能研究

采用分步沉淀法制备了担载CuO和ZnO的ZrO2基纳米催化吸收剂，对其结构和物相的变化进行了表征，并在模拟烟气中采用气相色谱仪研究了其脱除SOz的性能差别。结果表明，分步沉淀法制得的担载CuO和ZnO的ZrO2基纳米粉体的晶粒小于20mm，形貌多为球形或椭球形状，其中ZnO／ZrO2纳米粉体晶粒间有较大的团聚现象。对于纳米CuO／ZrO2催化吸收剂而言，比表面积越大，试样的脱硫率越高；而纳米ZnO／ZrO2粉体在200℃左右脱硫率达到最大，且随着温度的升高，脱硫率逐渐下降。当活性组分负载量为5％时，两种不同类型的催化吸收剂脱硫率均达到最高，稳定性也最好。相比之下，CuO／ZrO2纳米催化吸收剂适合于中温脱硫，而ZnO／ZrO2纳米催化吸收剂可在低温下更好地脱硫。     

Graded plasma spraying of premixed metalceramic powders on metallic substrates

The mismatch between the thermal expansion coefficients of ceramics and metals and the differential stresses it causes at the interface create problems in metal to ceramic joining. Research has been con-ducted to solve this problem in thermal barrier coating technology. Previous studies have considered met-al-ceramic multilayers or graded-coatings, which include a metallic bond coat. In this study, a graded plasma-sprayed metal-ceramic coating is developed using the deposition of premixed metal and ceramic powders without the conventional metallic bond coat. Influences of thickness variations, number, and composition of the layers are investigated. Coatings are prepared by atmospheric plasma-spraying on In-conel 718 superalloy substrates. Ni-Cr-Al and ZrO₂ -8 % Y₂O₃ powders are used for plasma spraying. Ad-hesive and cohesive strength of the coatings are determined. The concentration profile of the elements is determined by x-ray energy-dispersive analysis. The microstructure and morphology of the coatings are investigated by optical and scanning electron microscopy (SEM). Results show that the mixed metal-ce-ramic coating obtained with the deposition of premixed powders is homogeneous. The morphology and microstructure of the coatings are considered satisfactory.     

Penetration treatment of plasma-sprayed ZrO2 coating by liquid Mn alloys

The penetration phenomena of liquid manganese (Mn) alloy into porous ZrO₂ (8 vvt % Y₂O₃) coating plasma sprayed on SS400 steel substrate was studied by heating in a vacuum atmosphere. The improvement in mechanical properties of the coating by heat treatment with liquid Mn alloys was examined. Liquid Mn alloys, such as Mn-Cu, Mn-Sn, and Mn-In, rapidly penetrated the coating and formed a chemical bond between the coating and the substrate. The densification of the ZrO₂ coating occurred when ZrO₂ particles were sintered with liquid Mn alloys that penetrated the porous coating. The dense coating was free of porosity, and its hardness increased after heat treatment with Mn alloys, compared with assprayed ZrO₂ coating. Moreover, the fracture toughness of the coating reached the same levels as those of sintered yttria-stabilized PSZ.     

Grinding induced effects in plasma sprayed zirconia coatings

The effect of grinding on the surface layer properties of ceria and yttria partially stabilized zirconia plasma-sprayed coatings (CePSZ, YPSZ, respectively) has been studied by X-ray diffraction methods. For this purpose, the modified model of line broadening analysis has been derived. The model considers elastic anisotropic properties along with more random paracrystal imperfections, both affecting X-ray line broadening. Grinding-induced microstructural changes were also studied using an estimation from the quantitative Orientation Distribution Function (ODF) texture. It was concluded, based on this work, that CePSZ ceramic is less mechanically stable compared to YPSZ. Consequently, more beneficial mechanical properties of a ground surface layer can be expected for CePSZ plasma-sprayed coatings.     

Isothermal oxidation of physical vapor deposited partially stabilized zirconia thermal barrier coatings

Thermal barrier coatings (TBCs), consisting of physical vapor deposited (PVD) partially stabilized zirconia (PSZ, 8 wt.%Y₂O₃) and a diffusion aluminide bond coat, were characterized as a function of time after oxidative isothermal heat treatment at 1373 K in air. The experimental characterizations was conducted by X-ray diffraction analysis and scanning electron microscopy (SEM) with energy-dispersive spectroscopy. During cooling to room temperature, spallation of the PSZ ceramic coatings occurred after 200 and 350 h of isothermal heat treatment. This failure was always sudden and violent, with the TBC popping from the substrate. The monoclinic phase of zirconia was first observed on the bottom surface of the PVD PSZ after 200 h of isothermal heat treatment. The failure of TBCs occurred either in the bond coat oxidation products of αAl₂O₃ and rutile TiO₂ or at the interface between the oxidation products and the diffusion aluminide bond coat or the PSZ coating.