Mechanical Properties and Residual Stress Depth Profiles of Plasma Sprayed Ceramic Coatings Deposited Under Comparable Particle Temperature and Velocity

Ghara, Tina; Bandyopadhyay, P.P.

doi:10.1007/s11666-022-01412-1

Cited by 5 publications

(4 citation statements)

References 66 publications

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“…On the other hand, higher plasma power associated with alumina and chromia coatings (Table 2) resulted in the full relaxation of residual stress in the corresponding substrates (Figure 2A,C). These results were also discussed in more detail in previous reports 25,32 . The obtained residual stress profiles in top coatings are quite in line with the profiles reported in the literature.…”

Section: Resultssupporting

confidence: 91%

“…These results were also discussed in more detail in previous reports. 25,32 The obtained residual stress profiles in top coatings are quite in line with the profiles reported in the literature. The observed trend of residual stress tending toward compression is similar to that obtained using numerical simulation by Zhu et al 33 in YSZ coating and Liu et al 34 in alumina coating.…”

Section: Full Residual Stress-depth Profilessupporting

confidence: 89%

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Adhesion in thermally sprayed coatings: An insight from interfacial residual stress

Ghara

Bandyopadhyay

2022

J Am Ceram Soc.

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A thermally sprayed coating consists of multiple layers of different materials, that is, topcoat, bondcoat, and substrate. These three layers form two different junctions, namely, topcoat-bondcoat, and bondcoat-substrate. The residual stress state in two different materials in the interfaces was investigated using a systematic X-ray diffraction-based procedure consisting of phase and stress analysis. A transfer of residual stress from one material to the other was found to take place at the interfaces. The residual stress state of the topcoat influenced the stress field of the bondcoat, whereas the residual stress of substrate was affected by the stress state of the bondcoat at the interfaces. It was also perceived that the residual stress field along the depth of a multilayer coating system can be measured using a single X-ray target with a proper investigation procedure, eliminating the need of using different X-ray sources for different materials. It was found that the residual stress from one material transfers to another, and in the process, clamping of one surface by the other takes place at multiple locations throughout the surface. This is how mechanical interlocking between two layers takes place. Thus, the result can provide a basic understanding on the micro-mechanism of coating adhesion.

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Section: Resultssupporting

confidence: 91%

Section: Full Residual Stress-depth Profilessupporting

confidence: 89%

Adhesion in thermally sprayed coatings: An insight from interfacial residual stress

Ghara

Bandyopadhyay

2022

J Am Ceram Soc.

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“…This might be attributed to the residual stress originating in the high temperature gradients between the coating and substrate. Rapid cooling of particles generates quenching stress due to constrained volume change [23]. In addition, thermal stress arises from a mismatch between TEC of substrate and coating [24].…”

Section: Microstructural Analysismentioning

confidence: 99%

“…In addition, thermal stress arises from a mismatch between TEC of substrate and coating [24]. When a critical stress level is reached, it is expected that vertical cracks are formed as a relaxation mechanism [23,25]. From the optical micrographs, no oxidation layer between Cu and Al 2 O 3 is detectable.…”

Section: Microstructural Analysismentioning

confidence: 99%

Metastable Phase Formation, Microstructure, and Dielectric Properties in Plasma-Sprayed Alumina Ceramic Coatings

et al. 2022

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The need for new solutions for electrical insulation is growing due to the increased electrification in numerous industrial sectors, opening the door for innovation. Plasma spraying is a fast and efficient way to deposit various ceramics as electrical insulators, which are used in conditions where polymers are not suitable. Alumina (Al2O3) is among the most employed ceramics in the coating industry since it exhibits good dielectric properties, high hardness, and high melting point, while still being cost-effective. Various parameters (e.g., feedstock type, spray distance, plasma power) significantly influence the resulting coating in terms of microstructure, porosity, and metastable phase formation. Consequently, these parameters need to be investigated to estimate the impact on the dielectric properties of plasma-sprayed alumina coatings. In this work, alumina coatings with different spray distances have been prepared via atmospheric plasma spray (APS) on copper substrates. The microstructure, porosity, and corresponding phase formation have been analyzed with optical microscopy, X-ray diffraction (XRD), and scanning electron microscopy (SEM). Moreover, we present an in-depth analysis of the fundamental dielectric properties e.g., direct current (DC) resistance, breakdown strength, dielectric loss tangent, and permittivity. Our results show that decreasing spray distance reduces the resistivity from 6.31 × 109Ωm (130 mm) to 6.33 × 108Ωm (70 mm), while at the same time enhances the formation of the metastable δ-Al2O3 phase. Furthermore, space charge polarization is determined as the main polarization mechanism at low frequencies.

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Effect of spray parameters on the microstructure, solid lubricant phase retention, and high-temperature tribological performance of plasma sprayed YSZ/BaF2 composite coatings

Das,

Sarkar,

Bandyopadhyay

2024

Journal of the European Ceramic Society

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Mechanical Properties and Residual Stress Depth Profiles of Plasma Sprayed Ceramic Coatings Deposited Under Comparable Particle Temperature and Velocity

Cited by 5 publications

References 66 publications

Adhesion in thermally sprayed coatings: An insight from interfacial residual stress

Adhesion in thermally sprayed coatings: An insight from interfacial residual stress

Metastable Phase Formation, Microstructure, and Dielectric Properties in Plasma-Sprayed Alumina Ceramic Coatings

Effect of spray parameters on the microstructure, solid lubricant phase retention, and high-temperature tribological performance of plasma sprayed YSZ/BaF2 composite coatings

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