Abstract
Plasma sprayable α-alumina powder was prepared by spray drying process. The powder was characterized by field emission scanning electron microscopy (FESEM), powder X-ray diffractometry, particle size analysis and flowability measurement. In the present work, the influences of three different critical plasma spray parameter (CPSP) values (675, 825 and 937.5 W/nl.pm) on the crystallographic forms, microstructure, microhardness, surface roughness, wear and corrosion resistance of the plasma sprayed alumina coatings were investigated. The coatings were characterized by X-ray diffractometry and the analysis revealed the presence of some traces of γ-alumina along with α-alumina for the coating obtained at higher CPSP. The surface roughness, microhardness, corrosion and wear resistance of the coatings were evaluated. Plasma sprayed alumina coating obtained at the highest CPSP exhibited improved wear and corrosion resistance compared to the other two coatings which is attributed to the dense nature of the coating.
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