Abstract
A YSZ-Al reactive system was used as raw materials for the fabrication of a novel YSZ-Al2O3 composite coating by plasma spraying. Thermite reaction was triggered in the plasma jet and phases like alumina and Zr–Al intermetallics were in-situ formed in the reaction zone. Solid solution reaction occurred in the rapid solidification of the homogeneously mixed Y–Al–Zr–O superheated melt and high solubility of Al3+ was also observed in the supersaturated solid solution. Phase transitions from the reactive precursor to the coating composition and the microstructure formation of the coating lamellae were revealed by extensive characterizations including XRD, XPS, Raman, SEM, EDS, and EPMA. Good compatibility within the coating compositions and compact interlamellar bonding were obtained in the as-prepared YSZ-Al2O3 composite coating. The coating's surface and cross-section Vickers hardness values were 7.48 GPa and 10.40 GPa, respectively. Additionally, the micro-zone hardness value of the eutectic area could reach 19.43 GPa.
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