Study of the Structure and Properties of Multilayer Plasma Powder Coatings of Ceramics and Nickel-Based Alloys

Abstract

The paper deals with the studies of plasma coatings formed under optimal technological conditions from Al2O3–TiO2–NiCrAlYТа powder compositions. They have an acceptable density and have a number of surface defects acceptable for operation – pores and cracks. Large-dimensional ceramic Al2O3–TiO2 particles are embedded in the NiCrAlYТа matrix during the formation of the coating. This structure is associated with the mobility of the molten liquid-phase components of NiCrAlYТа, which tend to fill gaps and cracks that occur during plasma spraying of metal oxide coating and contribute to an increase in the density of coatings. In the process of high-temperature deposition, the oxide component melts into an organic whole with a metal one in the area of the interface, the elements diffuse and penetrate each other, so the interface is not clearly defined, there are no obvious boundaries between layered structures. These structures, along with chemical and mechanical bonds, also contain metallurgical bonds. With the optimal spraying parameters we have established, a microheterogeneous structure is observed in the coating system with the content of elements that ensure its wear resistance (orthorhombic phase of titanium oxide, Cr1.12Ni2.88, a-Al2O3, γ-Al2O3). Spreading of molten powder particles on the substrate occurs with minimal spattering and losses upon impact on the substrate. The main crystalline phases in the system of the formed coating include Cr1.12Ni2.88, γ-Al2O3, anatase (TiO2) in addition to rutile, and a-Al2O3. In the analysis, diffraction peaks in rutile are detected in the ranges 2θ = 32° and 2θ = 70°, while the content increases after the sputtering process, which confirms the transition from the anatase phase to the rutile phase at high temperature. Based on the results of quantitative analysis, the content in coating of a-Al2O3 and rutile TiO2 is approximately 30.4 % and 32.2 %, respectively, being the main phase structures of the coatings. Studies have been carried out on the influence of distances of the plasma spraying process on the performance characteristics of wear-resistant plasma coatings – adhesion strength, hardness and porosity.