Functional properties of ceramic-Ag nanocomposite coatings produced by magnetron sputtering

In recent years, the use of nanocomposite materials to functionalize surfaces has been investigated, taking advantage of the complementary properties of the nanocomposite constituents. Among this family of materials, ceramic-Ag coatings have been widely studied due to the large variety of functionalities that silver possesses and the possibility of tuning the coating’s practical features by selecting the proper matrix to support this noble metal. Therefore, this review focuses on the effects of silver nanoparticles on the functional properties of ceramic-Ag nanocomposites. The chemistry, structure, morphology and topography of the coatings are analyzed with respect to the changes produced by the silver nanoparticles’ distribution, amount and sizes and by altering production process variables. To offer a clear understanding of the functionalities of these materials, the optical, electrical, mechanical, tribological, electrochemical and biological properties reported in the last decade are reviewed, focusing on the ability to tune such properties by modifying the silver distribution, morphology and composition. In particular, the surface plasmon resonance, self-lubricating ability and antibacterial effect of silver are covered in detail, establishing their correlation with factors such as silver diffusion, segregation and ionization.     

A NUMERICAL STUDY ON THERMAL FRACTURE OF PRECRACKED CERAMIC COATINGSIN HIGH-HEAT-FLUX ENVIRONMENT

The thermomechanical fracture and interface delamination of thermal barrier coatings (TBCs) in a high-heat-flux environment is the result of large surface temperature and thermal gradient across the coating thickness and the resulting viscoplastic deformations induced in the ceramic material. The maximum coating surface temperature has been used as the key loading parameter in previous studies. The current study explores the effects of several other thermal loading parameters on thermomechanical response and fracture behavior of TBCs with or without preexisting surface cracks. Results show that for a constant maximum surface temperature, the thermal fracture of the coating is increased by (i) an increased temperature difference across the coating, (ii) longer heating duration, and (iii) more aggressive coating surface cooling after heating. These results provide insights into TBC thermal fracture mechanisms and can potentially improve the design of the morphology of preexisting cracks in the coating to reduce fatal interface fracture.     

A simple non-destructive method to indicate the spallation and damage degree of the double-ceramic-layer thermal barrier coating of La2(Zr0.7Ce0.3)2O7 and 8YSZ:Eu

Double-ceramic-layer (DCL) thermal barrier coatings (TBCs) of La₂(Zr_0.7Ce_0.3)₂O₇ (LZ7C3) and Eu³⁺-doped zirconia, which was partially stabilised by 8 wt% yttria (8YSZ:Eu), were prepared by atmospheric plasma spraying. A thermal cycling test was carried out. The 8YSZ:Eu sublayer exposed during thermal cycling could produce visible luminescence under ultraviolet (UV) illumination, providing an indication of the spallation and damage degree of the coating. The result shows that the application of a Eu³⁺-doped luminescence sublayer can be a very simple and useful non-destructive technique to indicate the spallation and damage degree of DCL coatings.     

Thermo-physical properties of plasma sprayed Yttria Stabilized Zirconia Coatings

This article investigates the thermo-physical properties of plasma sprayed zirconia coatings produced by agglomerates of submicron size particles as the feedstock. The microstructure of these deposits is consisted of splats and non-molten particles. This bimodal structure generally shows a better performance than conventional coatings. The agglomerated feedstock with internal submicron size porosity may significantly affect porosity related properties, such as the thermal diffusivity. In this study different process parameters were used to deposit yttria stabilized zirconia coatings with conventional and bimodal structures. Results showed a good correlation between the shape and distribution of pores and thermal diffusivity of the coatings.     

Copper-Tungsten Composites Sprayed by HVOF

Copper and copper-tungsten composite coatings were produced by high-velocity oxy-fuel spraying (HVOF). After initial optimization of the spraying parameters, coatings of various compositions were made and their structure, composition, mechanical, thermal, and electrical properties were characterized. The HVOF technique was able to produce rather dense coatings with minimal oxide content and relatively good mechanical and thermal properties compared to, for example, plasma-sprayed coatings; however, the achieved tungsten content was quite low.     

Influence of tungstate ion dopants in corrosion protection behavior of polyaniline coating on mild steel

Electropolymerization of polyaniline (PANI) and polyaniline‐tungstate (PANIW) coatings on mild steel were successfully performed using cyclic voltammetry technique. Processes were carried out in aqueous electrolyte solutions of 0.3 M oxalic acid + 0.1 M aniline and 0.3 M oxalic acid + 0.1 M aniline + 0.001 M sodium tungstate dehydrate. Corrosion protection of PANI and PANIW coatings was evaluated with the help of open circuit potential (E_ocp) monitoring and electrochemical impedance spectroscopy (EIS) methods. All the results reveal the influence of additional doping agent (i.e., tungstate) in corrosion protection behavior of PANI coating.     

Effectiveness of platinum and iridium in improving the resistance of Ni‐Al to thermal cycling in air–steam mixtures

The aim of this work was to assess the value of platinum and iridium additions, with and without hafnium, to binary Ni‐Al alloys, intended to act as models for aluminide coatings. Attention was focused on a (γ + γ′) Ni‐22Al alloy, but comparisons were made with β‐Ni‐50Al. All compositions are given in at%. Alloys were exposed to flowing gases at a total pressure of 1 bar for one thousand 1 h cycles at 1200 °C. Compared to binary Ni‐Al alloys, the Pt‐modified alloys performed much better (with or without Hf) in dry air. Thermal cycling in air + 12% H₂O led to more rapid weight losses, due to enhanced spalling. Again, the addition of Pt was beneficial, but weight losses were still significant in the absence of Hf additions. A Ni‐22Al‐15Pt + Hf alloy slowly lost weight by scale spallation over 1000 cycles, but a Ni‐22Al‐30Pt + Hf alloy resisted weight loss. Partial substitution of Ir for Pt was beneficial in both wet and dry air. However, in the case of wet air, Hf additions were necessary to prevent slow spallation losses.     

Corrosion behaviour of boiler steels,coatings and welds in flue gas environments

In recent years there has been a steadily increasing focus on energy efficiency as a means to reduce the negative impact of human activity on climate, and in particular the effect that industrial emissions have on changes in the climate, specifically global warming. As far as power generation is concerned, emissions can be limited by maximizing energy efficiency while ensuring high levels of plant reliability. This paper reports on materials development work involving coated heat exchange alloys and the effect of welding of the coated alloys, simulating fabrication, on subsequent corrosion performance under laboratory conditions. Samples of the common boiler steels P91 (9% Cr) and HCM12A (12% Cr) were treated by chemical vapour deposition (CVD) in a pack cementation process to produce Al‐rich coatings up to 100 µm thick. The samples were machined to give bevelled edges for welding. Welding was carried out using commonly available alloy 625 filler metal. It was found that sound weldments could readily be produced provided that care was taken to limit the heat input during the welding process. Excessive heat input could lead to cracking, but more importantly to dilution of Al in the coating adjacent to the weldment and in segregation of elements (Mo and Nb) in the weldment itself. Both dilution and segregation effects led to decreased corrosion resistance.     

Effect of microstructure and temperature on the erosion rates and mechanisms of modified EB PVD TBCs

Thermal barrier coatings (TBCs) have now been used in gas turbine engines for a number of decades and are now considered to be an accepted technology. As there is a constant drive to increase the turbine entry temperature, in order to increase engine efficiency, the coatings operate in increasingly hostile environments. Thus there is a constant drive to both increase the temperature capabilities of TBCs while at the same time reducing their thermal conductivities. The thermal conductivity of standard 7 wt% yttria stabilized zirconia (7YSZ) electron beam (EB) physical vapour deposited (PVD) TBCs can be reduced in two ways: the first by modification of the microstructure of the TBC and the second by addition of ternary oxides. By modifying the microstructure of the TBC such that there are more fine pores, more photon scattering centres are introduced into the coatings, which reduce the heat transfer by radiation. While ternary oxides will introduce lattice defects into the coating, which increases the phonon scattering, thus reducing the thermal conductivity via lattice vibrations. Unfortunately, both of these methods can have a negative effect on the erosion resistance of EB PVD TBCs.This paper compares the relative erosion rates of ten different EB PVD TBCs tested at 90° impact at room temperature and at high temperature and discusses the results in term of microstructural and temperature effects. It was found that by modifying the coating deposition, such that a low density coating with a highly ‘feathered’ microstructure formed, generally resulted in an increase in the erosion rate at room temperature. When there was a significant change between the room temperature and the high temperature erosion mechanism it was accompanied by a significant decrease in the erosion rate, while additions of dopents was found to significantly increase the erosion rate at room and high temperature. However, all the modified coatings still had a lower erosion rate than a plasma sprayed coatings. So, although, relative to a standard 7YSZ coating, the modified coatings have a lower erosion resistance, they still perform better than PS TBCs and their lower thermal conductivities could make them viable alternatives to 7YSZ for use in gas turbine engines.