Abstract
Ceramic and metal composites, known also as cermets, may considerably improve many material properties with regards to that of initial components. Hence, cermets are frequently applied in many technological fields. Among many processes which can be employed for cermet manufacturing, thermal spraying is one of the most frequently used. Conventional plasma spraying of powders is a popular and cost-effective manufacturing process. One of its most recent innovations, called solution precursor plasma spraying (SPPS), is an emerging coating deposition method which uses homogeneously mixed solution precursors as a feedstock. The technique enables a single-step deposition avoiding the powder preparation procedures. The nanostructured coatings developed by SPPS increasingly find a place in the field of surface engineering. The present review shows the recent progress in the fabrication of cermets using SPPS. The influence of starting solution precursors, such as their chemistry, concentration, and solvents used, to the micro-structural characteristics of cermet coatings is discussed. The effect of the operational plasma spray process parameters such as solution injection mode to the deposition process and coatings’ microstructure is also presented. Moreover, the advantages of the SPPS process and its drawbacks compared to the conventional powder plasma spraying process are discussed. Finally, some applications of SPPS cermet coatings are presented to understand the potential of the process.
Highlights
Recent studies demonstrate that deposition of coatings composed of metal phase embedded in ceramic matrix have considerably improved properties, such as hardness, wear resistance, surface reactivity, etc. [1,2,3,4,5,6,7,8,9,10]
Atmospheric plasma spraying (APS) is a conventional thermal spray process which has been widely, and for many years, used for deposition of cermets used as protective coatings [1,3], thermal barrier coatings [4,5,6], and coatings in solid oxide fuel cells (SOFC) [7,8,9]
The present review focuses the current progress of solution precursor plasma spray for depositing cermet coatings used in on the current progress of solution precursor plasma spray for depositing cermet coatings used in various applications
Summary
Recent studies demonstrate that deposition of coatings composed of metal phase embedded in ceramic matrix have considerably improved properties, such as hardness, wear resistance, surface reactivity, etc. [1,2,3,4,5,6,7,8,9,10]. The production of coatings with fine microstructures (sub-micrometer/nanometer-scale) has been developed since the mid-1990s These coatings improved its physical and mechanical properties, such as surface area, solubility, and many others [11,12,13,14,15,16,17,18,19,20]. Metals 2018, 8, x FOR PEER REVIEW precursor has been developed to overcome the limitations of theofAPS precursor plasma plasmaspraying sprayingprocess process(SPPS),. The review gives an overview of the various factors affecting the final coating coating material, material,such suchasassolution solutionprecursor precursor preparations and physico-chemical interaction of final preparations and physico-chemical interaction of the the solution precursor with the high-temperature plasma jet.
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