Abstract
This study presents a new thermal spray coating manufacturing process to deposit high performance ceramic coatings named ‘Hybrid-LVOF’ (Low Velocity OxyFuel). By this process, both thin and thick ceramic coatings can be deposited on metallic or ceramic substrates. In this work, the microstructural and mechanical properties of H-LVOF sprayed Al2O3-TiO2 coatings were compared with plasma sprayed (PS) Al2O3-TiO2 coatings; with the additional condition that typical bond coat was not applied. The α-Al2O3 and γ-Al2O3 contents have been quantified in the as-sprayed coatings. As-sprayed Hybrid-LVOF coatings show better properties than conventional plasma-sprayed coatings including better fracture toughness. Noise and radiation levels are very low in the hybrid-LVOF process. Furthermore, a 50% reduction in overall production cost was achieved. H-LVOF could be therefore a possible alternative to a conventional plasma spray process.
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