Abstract
This research is focused on the application of the Al2O3-phosphate ceramic coating on mild steel surface to protect mild steel from erosion in coal dust environment. Erosion resistance of mild steel could be improved by overlay it with SiC in the Al2O3-phosphate ceramic coating. As a filler, Al2O3 was mixed with 20%, 40%, and 60% SiC by using aluminium phosphate as a binder and heated at 220 °C for 5 hours. X-ray diffraction testing was conducted to observe the phase of Al2O3-SiC phosphate ceramic coating. Meanwhile, surface morphology and adhesion characteristic of Al2O3-SiC phosphate ceramic coating were analyzed by scanning electron microscope. To analyze the erosion resistance quantitatively solid particle impingement test by applying gas jets at the right angle (90°) against a sample surface has been conducted. The results showed that Al2O3-SiC phosphate ceramic coating is strongly bound to the mild steel surface without the presence of any void. The higher the SiC content can increase the ceramic coating density and its erosion resistance. The SiC 60% produces four times higher erosion resistance than uncoated mild steel. The material characterization of Al2O3-SiC phosphate ceramic coating proves that SiC gives a significant impact on the enhancement of erosion resistance of the Al2O3-SiC phosphate ceramic coating.
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