Abstract
Dense and nanostructured YSZ-ZrC composite coatings were reactively synthesized by atmospheric plasma spraying. Reactive YSZ-Al-SiC precursors with different YSZ contents were used and the evolution of the phase, microstructure and mechanical properties of the as-prepared coatings were fully revealed. Phase transformation for the YSZ component, from tetragonal phase in the start material to cubic phase in the composite coating, was validated by experimental evidences. It could be explained that the progression of in-situ reactions consumed considerable volume of zirconia and then led to higher Y/Zr ratio of Y-Zr-O melt in the droplets and then cubic phase was retained. Based on the content regulation of the reactive components, the highest yielding of ZrC phase was 35.4 wt% and the highest microhardness and fracture toughness of the composite coatings were 823 HV0.1 and 2.79 MPa/m2.
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