Abstract
In this work, dense zircon-based ceramic coatings were obtained from inexpensive zircon powder on a steel substrate by using a new multi-chamber gas-dynamic accelerator. The microstructure and phase composition of the coating were characterized by scanning electron microscopy, optical microscopy, and X-ray diffraction. The mechanical properties of the coatings were evaluated using microindentation, wear tests and bonding strength tests. The results showed that the obtained zircon-based ceramic coatings were continuous without cracks and bonded well with substrate without a sublayer. The zircon-based ceramic coatings consisted of c-ZrO2 (major phase), m-ZrO2 and SiO2. The zircon-based ceramic coatings had a porosity of 0.1%, hardness of 526 ± 65 HV0.2, and a fracture toughness of 2.5 ± 0.6 (МPа∙m1/2). The coatings showed the low specific wear rate and average erosion rate. The failure mode occurring in the tested coatings was cohesive.
Highlights
Zircon (ZrSiO4 ) is a natural mineral used for various applications as a refractory bulk material [1,2,3,4].The nominal chemical composition of zircon is 67.1 wt % ZrO2 and 32.9 wt % SiO2, but there are small amounts of Fe2 O3, cerium, thorium, or hafnium [1]
It was experimentally demonstrated that the zircon‐based ceramic coatings could be manufactured on corrosion resistant steel without a sublayer by a new multi‐chamber gas‐dynamic accelerator
The zircon‐based ceramic coatings were characterized by low porosity (0.1%), a relatively high
Summary
Zircon (ZrSiO4 ) is a natural mineral used for various applications as a refractory bulk material [1,2,3,4].The nominal chemical composition of zircon is 67.1 wt % ZrO2 and 32.9 wt % SiO2 , but there are small amounts of Fe2 O3 , cerium, thorium, or hafnium [1]. Zircon is among the most widely used and cheapest spray-coating material for refractory applications [5,6,7,8,9]. The sprayed zircon deposits were observed with all three modifications of zirconia (c-ZrO2 [17,19], m-ZrO2 [17], and t-ZrO2 [19]) [20]. Which of these phases will prevail in the plasma-prepared material depends on the technology of its preparation [5]
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