Development of suspension plasma sprayed alumina coatings with high enthalpy plasma torch

Tesař, Tomáš; Mušálek, Radek; Medřický, Jan; Kotlan, Jiří; Lukáč, František; Pala, Zdeněk; Ctibor, Pavel; Chráska, Tomáš; Houdková, Šárka; Římal, Václav; Curry, Nicholas

doi:10.1016/j.surfcoat.2017.06.039

Cited by 34 publications

(21 citation statements)

References 24 publications

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“…For instance, a nanocrystalline Inconel 718 coating deposited by high velocity oxygen fuel (HVOF) method exhibited a significant increase in hardness (by approximately 60%) over that of the Inconel 718 control sample [8]. Another results published in [9] showed that decreasing the grain size of Al 2 O 3 feedstock powder from ∼50 μm down to 300 nm increased the tensile adhesion strength of the deposited coating by a factor of three and the coating wear resistance was increased by a factor of ten. Nanostructured zirconia coatings deposited by plasma spraying in the study by Chen et al [10] showed that the wear rates of the nanostructured coatings were about 40% of those of traditional zirconia coatings under loads from 20 to 80 N. Owing to these outstanding performances, targeted applications have been successfully implemented for hard and wear-resistant ceramic coatings in industrial sectors in the past decade [6].…”

Section: Introductionmentioning

confidence: 99%

“…However, their tendency towards agglomeration as well as associated difficult handling and potential health risk of using such suspensions [11] triggered a shift to using sub-micrometric particles instead. Even though the coatings prepared by suspension plasma spraying route can often surpass the coatings prepared from dry powders [9], their industrial application remain rather scarce at the moment, owing to difficulties in the coating preparation and relatively low deposition rate (coating thickness increase per torch pass) compared to dry powder plasma spraying [12,13].…”

Section: Introductionmentioning

confidence: 99%

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Improvement of Mechanical Properties of Plasma Sprayed Al2O3–ZrO2–SiO2 Amorphous Coatings by Surface Crystallization

et al. 2019

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Ceramic Al2O3−ZrO2−SiO2 coatings with near eutectic composition were plasma sprayed using hybrid water stabilized plasma torch (WSP-H). The as-sprayed coatings possessed fully amorphous microstructure which can be transformed to nanocrystalline by further heat treatment. The amorphous/crystalline content ratio and the crystallite sizes can be controlled by a specific choice of heat treatment conditions, subsequently leading to significant changes in the microstructure and mechanical properties of the coatings, such as hardness or wear resistance. In this study, two advanced methods of surface heat treatment were realized by plasma jet or by high energy laser heating. As opposed to the traditional furnace treatments, inducing homogeneous changes throughout the material, both approaches lead to a formation of gradient microstructure within the coatings; from dominantly amorphous at the substrate–coating interface vicinity to fully nanocrystalline near its surface. The processes can also be applied for large-scale applications and do not induce detrimental changes to the underlying substrate materials. The respective mechanical response was evaluated by measuring coating hardness profile and wear resistance. For some of the heat treatment conditions, an increase in the coating microhardness by factor up to 1.8 was observed, as well as improvement of wear resistance behaviour up to 6.5 times. The phase composition changes were analysed by X-ray diffraction and the microstructure was investigated by scanning electron microscopy.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Improvement of Mechanical Properties of Plasma Sprayed Al2O3–ZrO2–SiO2 Amorphous Coatings by Surface Crystallization

et al. 2019

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“…It was found that finer porosity, smaller splat size, and enhanced interlamellar bonding observed in SPS alumina coatings led to improved scratch and wear resistance compared to APS alumina samples. In a study done by Tesar et al 30 both columnar and well‐sintered dense alumina microstructures were observed in suspension plasma sprayed alumina coatings. In this study, high enthalpy hybrid water‐stabilized plasma torch was used to spray several water‐based and ethanol‐based suspensions of α‐Al 2 O 3 submicrometer‐sized powders.…”

Section: Introductionmentioning

confidence: 96%

Microstructure, phase and dielectric strength of thermally sprayed alumina layers in coating‐based heating systems

Bajgiran

Rad

McDonald

et al. 2021

Int J Applied Ceramic Tech

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In coating‐based resistive heating systems applied on an electrically conductive substrate, an intermediary dielectric layer is required to minimize or eliminate leakage of current from the heating surface to the substrate. Aluminum oxide has widely been used for electrical insulation purposes. In this study, alumina was deposited onto carbon steel substrates by using suspension plasma spraying and flame spraying processes. Then, Ni‐20Cr, as the heating element, was deposited on the alumina layer by using air plasma spraying. The resultant microstructure and phase composition of the alumina layers were evaluated by using scanning electron microscope images, X‐ray diffraction analysis, and Raman spectroscopy. The breakdown voltage of alumina layers was measured independently and within the heating system. It was found that the dielectric properties of alumina layers were significantly affected by its microstructural features. It was observed that penetration of metal topcoat into the alumina layer decreased the overall breakdown voltage of the system.

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“…In recent years, SPS technique has been used for the production of a series of ceramic coatings, such as Al 2 O 3 , Ca(H 2 PO 4 ) 2 , and ZrO 2 . So YAG coating is likely to be synthesized by plasma spraying Y 2 O 3 and Al 2 O 3 suspension.…”

Section: Introductionmentioning

confidence: 99%

“…In recent years, SPS technique has been used for the production of a series of ceramic coatings, such as Al 2 O 3 , Ca (H 2 PO 4 ) 2 , and ZrO 2 . [26][27][28] So YAG coating is likely to be synthesized by plasma spraying Y 2 O 3 and Al 2 O 3 suspension. In current investigation, YAG coating is attempted to be prepared by SPS method using Y 2 O 3 and Al 2 O 3 nanometer powders suspension.…”

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confidence: 99%

Phase composition, structural, and plasma erosion properties of ceramic coating prepared by suspension plasma spraying

Zhao

Wang

Chen

et al. 2018

Int J Applied Ceramic Tech

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Y3Al5O12 (YAG), Y2O3, and Al2O3 ceramic coatings were manufactured to investigate the plasma erosion properties. The X‐Ray Diffraction (XRD) analysis confirmed that YAG coating was synthesized successfully by Y2O3 and Al2O3 mixture suspension using the plasma spraying method. Meanwhile, metastable phases were found in Y2O3 and Al2O3 coatings due to the quenching in cooling process of melted droplets. The coating surface morphology and microstructure of cross sections were characterized by SEM. The results reveal that coatings are composed by ultrafine splats and exhibit dense lamellar structure. The plasma erosion properties were evaluated at different etching test power under Ar/CF4/O2 plasma gas. The experimental results clarify that both of YAG and Y2O3 coatings show the better plasma erosion resistance than Al2O3 coatings. The formation of fluorination layer surface prevents the coatings from further erosion with plasma gas. Moreover, the etching rate of coatings depended on the fluorination and removing rate of fluoride layer.

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Development of suspension plasma sprayed alumina coatings with high enthalpy plasma torch

Cited by 34 publications

References 24 publications

Improvement of Mechanical Properties of Plasma Sprayed Al2O3–ZrO2–SiO2 Amorphous Coatings by Surface Crystallization

Improvement of Mechanical Properties of Plasma Sprayed Al2O3–ZrO2–SiO2 Amorphous Coatings by Surface Crystallization

Microstructure, phase and dielectric strength of thermally sprayed alumina layers in coating‐based heating systems

Phase composition, structural, and plasma erosion properties of ceramic coating prepared by suspension plasma spraying

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