Abstract
Electrophoretic deposition (EPD) was employed to coat yttria-stabilised zirconia (YSZ) on Fecralloy. Various non-aqueous solvents were utilised to achieve smooth crack-free YSZ coatings. The EPD parameters, including solvent type, sedimentation height, zeta potential, particle size, pH and deposition weight, were studied. The micro-structural evolution and mechanical properties of the coatings were studied by the field emission scanning electron microscopy and micro-hardness, respectively. It was found that coatings obtained from 0.4 g L−1 I2 acetyl–acetone were uniform, smooth and crack free. Also they had narrow particle size distributions and higher zeta potential in the suspension. The experimental results revealed that suspension stability was a requirement for obtaining high-quality coatings and deposition yield for stable suspensions was higher; however, particle coagulation resulted in coatings with low green density and poor sinter ability. A transition in deposition mechanism from linear to parabolic was observed during EPD where deposition rate was decreased by time.
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