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.