Studies of the microstructure and properties of dense ceramic coatings produced by high-velocity oxygen-fuel combustion spraying

Kulkarni, Anand; Gutleber, J.; Sampath, Sanjay; Goland, A.N.; Lindquist, W. Brent; Herman, H.; Allen, Andrew J.; Dowd, Betsy A.

doi:10.1016/j.msea.2003.10.295

Cited by 92 publications

(47 citation statements)

References 21 publications

(36 reference statements)

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“…This impeded them from adhering on the coating surface and probably caused them to behave as hot grit-blasters, lowering substantially the DE values. Previous studies have observed that for obtaining ''optimized" coatings during HVOF-spraying of pure ceramic oxides (e.g., TiO 2 , , particle size ranges from about 5 to 25 lm had to be employed [10][11][12][13][14]. However, as shown in the next sections, HVOF-sprayed Nano and PF particles exhibited dense and uniform microstructures, despite the fact that particles larger than the 5-25 lm distribution were employed ( Table 1).…”

Section: Titania Powdersmentioning

confidence: 77%

Process–property–performance relationships for titanium dioxide coatings engineered from nanostructured and conventional powders

Lima¹,

Marple²

2008

Materials & Design

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Nanostructured (Nano), fused and crushed (F&C) and plasma-fused (PF) titania (TiO 2 ) powder particles were thermally sprayed via flame spray (FS), air plasma spray (APS) and high velocity oxy-fuel (HVOF) on low carbon steel substrates. Flame spray processing, although widely employed industrially, generally has received very limited attention in academic papers. However, the results of this research have demonstrated that a FS Nano titania coating was the best performing among all coatings tested, exhibiting no measurable signs of mass/volume loss after dry-sliding wear testing (ball-on-disk) and the highest deposition efficiency (DE) level. This is regarded as an important result, considering the fact that among these three processing techniques FS is the least expensive, the most portable and exhibits the lowest energy consumption levels. In addition, scanning electron microscopy (SEM) analysis demonstrated that the sliding wear scars of the FS and HVOF-sprayed Nano coatings were smooth, without significant irreversible deformation or formation of ridges. These characteristics are not typical of ceramic materials. It is hypothesized that this plastic-like behaviour and resilience exhibited by FS and HVOF-sprayed Nano coatings explain their improved performance under dry-sliding wear.Crown

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Section: Titania Powdersmentioning

confidence: 77%

Process–property–performance relationships for titanium dioxide coatings engineered from nanostructured and conventional powders

Lima¹,

Marple²

2008

Materials & Design

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“…Experiments of Kulkarni et al [17], show the well layered microstructure of alumina deposited by high velocity oxy-fuel (HVOF) illustrates lower thermal conductivity than that of atmospheric plasma sprayed coating. Wang et al [11] quantified the effect of splat interfaces and reached the same conclusion.…”

Section: Discussionmentioning

confidence: 99%

Thermo-physical properties of plasma sprayed Yttria Stabilized Zirconia Coatings

Soltani

Coyle

Mostaghimi

et al. 2008

Surface and Coatings Technology

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“…International Figure 3 summarizes the residual strain results for both coatings, plotted on log-scale to highlight the differences in coating strain. These strain values illustrate the combined effect of phase transformations, thermal mismatch, peening effect, quenching of lamellas and differences in the coefficient of thermal expansion (CTE) of the coating substrate system [1][2][3] ) had a significant influence on the net residual strain in the coating layer. The average residual strain in the HVOF coating changes from tensile to compressive, whereas the average strain in the APS coating is tensile balanced by a corresponding opposite strain in the substrate.…”

Section: Coating Microstructurementioning

confidence: 94%

“…Non-destructive through thickness residual strain measurements in thermal spray coatings is possible via the high penetration depth achieved by the neutron diffraction technique [1][2]. The influence of coating process parameters on the residual stress fields of Al 2 O 3 coatings has been a topic of research of previous investigations [3]. Recent advancements in high velocity oxy-fuel (HVOF) technique has made it possible to deposit much finer alumina powders at relatively lower temperatures than those achieved by air plasma spraying (APS) process [4].…”

mentioning

confidence: 99%

Neutron diffraction residual strain measurements in alumina coatings deposited via APS and HVOF techniques

Ahmed

Faisal

Reuben

et al. 2010

J. Phys.: Conf. Ser.

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Abstract. Residual strains in air plasma sprayed (APS) and high velocity oxy-fuel (HVOF) alumina (Al 2 O 3 ) coatings were investigated by means of neutron diffraction technique. Results of this investigation conclude that through thickness residual strain in the APS coating was mainly tensile whereas the HVOF coating had both compressive and tensile residual strain. Further analysis of Vickers indentation fracture behaviour using acoustic emission (AE) technique concluded that the nature and magnitude of these residual strain fields had a direct effect on the fracture response of two coatings during the indentation process. IntroductionThermally sprayed alumina (Al 2 O 3 ) coatings are used in industry for thermal and electrical resistance applications. Measurement of residual strains in these coatings is critical for modeling and designing improved components. Non-destructive through thickness residual strain measurements in thermal spray coatings is possible via the high penetration depth achieved by the neutron diffraction technique [1][2]. The influence of coating process parameters on the residual stress fields of Al 2 O 3 coatings has been a topic of research of previous investigations [3]. Recent advancements in high velocity oxy-fuel (HVOF) technique has made it possible to deposit much finer alumina powders at relatively lower temperatures than those achieved by air plasma spraying (APS) process [4]. This has the effect of limiting phase transformations during coating deposition, which along with the relatively higher velocity and lower temperature of HVOF process can influence residual stress behavior. This paper therefore aims to investigate the through thickness changes in the residual strain profile of finer powder and conventional Al 2 O 3 coatings deposited by the HVOF and APS processes, respectively. Further analysis interlinking fracture behavior and residual strain is also presented.

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Studies of the microstructure and properties of dense ceramic coatings produced by high-velocity oxygen-fuel combustion spraying

Cited by 92 publications

References 21 publications

Process–property–performance relationships for titanium dioxide coatings engineered from nanostructured and conventional powders

Process–property–performance relationships for titanium dioxide coatings engineered from nanostructured and conventional powders

Thermo-physical properties of plasma sprayed Yttria Stabilized Zirconia Coatings

Neutron diffraction residual strain measurements in alumina coatings deposited via APS and HVOF techniques

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