Abstract
Glass coatings on carbon steel substrates have been produced by spraying glass feedstock powders using combustion flame spraying. Glass powders with different compositions and particle size were tested; coatings with increasing soft glass A volume fractions in hard glass B base (0%, 10%, 20%, 30%) were sprayed. Furthermore, two different particle size (53-63 µm and <45 µm) of 30wt%A glass feedstock powders were employed. The microstructures of coatings were examined, characterised and the porosity was quantified. Vickers microhardness, fracture toughness and adhesion strength have been measured. The comparisons between the microstructure of coatings produced by conventional enamelling and thermally sprayed were investigated. Uniform structure and large pores produced in conventional enamels and non-uniform structure with small size pores produced in thermally sprayed coatings. It was observed that adhesion strength increased, hardness decreased and the fracture toughness did not change with increasing glass A content. Refining particle size of 30wt%A glass composition increased the hardness and did not affect the adhesion and fracture toughness of coatings.
Highlights
Most of the applications of materials are limited by their resistance to aggressive environments
This is closely linked with the splat flattening on the substrate that increased with Glass A content and 30wt%A coating is expected to give better adherence with the substrate compared to other glass compositions
Glass feedstock and mixed powders of compositions 10wt%A, 20wt%A and 30wt%A in Glass B using size range 53-63 μm as well as glass feedstock powder of 30wt%A composition using size range 32-45 μm have been thermally sprayed on plain carbon steel substrates (50 × 40 × 1.5 mm) using combustion flame spraying
Summary
Most of the applications of materials are limited by their resistance to aggressive environments. The glass and the substrate are heated together one or more time in furnace to approximately 850 °C, whereas in combustion flame spraying the glass particles is melted in the flame and the temperature of the substrate is maintained at a relatively low level [3]. This has the potential of avoiding the need to heat the substrate to elevated temperature and evading the formation of fishscales and pinholes defects in coatings. The present work reports about the experimental characterization of the microstructural and mechanical properties of thermally sprayed coatings
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