Abstract
Zirconium carbide coatings were deposited on graphite substrates using the vacuum plasma spray process. Controlled vacuum spraying of pure compound powder was used to maintain the coating purity and to minimize the porosity of the sprayed carbide. Coating optimization studies were conducted using a Taguchi statistical fractional-factorial design of experiments. The effects of three plasma processing variables (i.e. gun current, argon primary gas flow, hydrogen secondary gas flow) were evaluated relative to the coating attributes of thickness, porosity, superficial hardness, and microhardness. As-sprayed coating qualities are discussed with respect to the influence of the processing parameters. In addition, the effect of annealing the carbide samples in an argon atmosphere at 1998 K, 2373 K, and 2673 K for 1 h was studied.
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