Abstract
In this study, the effects of the six technological parameters of atmospheric plasma spraying (including spraying current, spraying distance, main gas flow, auxiliary gas flow, spraying speed, and powder feeding rate) on the microhardness, density, and rate of deposition of nanoparticle cluster-oxidized yttria partially stabilized zirconia (YSZ) powder-ceramic coating were investigated through an orthogonal experiment. The structures of the powder and coating were observed by a scanning electron microscope. The hardness measurements were carried out on the samples, and the cross-section experimental results were analyzed by combining the structure of the coating and range analysis method, thereby obtaining the optimized technological parameters. The results show that the coating was primarily composed of melted ZrO2, and the coating section was a characteristic of concave–convex occlusions. Mechanical bonding played the dominant role. Main gas flow was the primary influencing parameter of performances of the atmospheric plasma spraying ZrO2 coating, followed by spraying current, auxiliary gas flow, powder feed rate, spraying speed, and spraying distance, successively. The optimal technological parameters for atmospheric plasma spraying ZrO2 coating were 75 standard cubic foot per hour (SCFH) of main gas flow, 875 A of spraying current, 45 SCFH of auxiliary gas flow, 30 g/min of powder feed rate, 400 mm/s of spraying speed, and 85 mm of spraying distance. The bonding microhardness, density, and rate of deposition of the prepared coating were HV388, 5.25 g/cm3, and 31.58%, respectively. The electrode potential and corrosion resistance of the prepared coating increased remarkably compared with that of the substrate, whereas the corrosion current decreased significantly.
Highlights
Magnesium alloy is an ideal and practical light structural material in high-tech fields and pillar industries
Magnesium alloy can be used as light shells and components of the damping system of aircrafts and spacecrafts
Magnesium alloy is widely used as an engineering structural material because
Summary
Magnesium alloy is an ideal and practical light structural material in high-tech fields (e.g., aviation, astronavigation, and electronics) and pillar industries (e.g., traffic transportation). Coatings 2020, 10, 1085 of its outstanding mechanical properties, the magnesium alloy parts fail because of different temperature, corrosion, and wearing resistances of substrate metals. Feng et al [9] prepared Al65 Cu23 Fe12 coatings on the AZ31 magnesium alloy surface by plasma spraying, which increased surface hardness and corrosion resistance . Ye et al [10] prepared a Al2 O3 + 3 wt.%TiO2 nano ceramic coating on the magnesium alloy surface by using the ordinary plasma spraying technology (substrate surface preprocessing–plasma spraying–thermal processing of coating), which increased surface hardness. A layer of YSZ thermal barrier coating was prepared on the VW75 magnesium alloy surface through plasma spraying, and the rank of technical parameters that influenced the performances of the coating was obtained through an orthogonal experiment. Appropriate plasma spraying parameters were optimized to prepare for follow-up services of the coating
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