Plasma Spray Process Research Articles

OPTIMIZATION OF EROSION–CORROSION BEHAVIOR OF NICHROME COATED 2205 DUPLEX STAINLESS STEEL USING GREY RELATIONAL ANALYSIS

Erosion–corrosion is a common mechanism in the degradation of systems in the mining, chemical, and petrochemical industries. Surface modification can help to reduce the detrimental effects of erosion–corrosion. This study uses the plasma spray process for coating nichrome on duplex stainless steel (DSS2205) to improve the surface characteristics. Erosion tests were performed to analyze the effect of parameters such as impact velocity (150, 175 and 200[Formula: see text]m/s), impact angle (30∘, 60∘and 90∘), and erodent particle discharge rate (2.5, 3.75 and 5[Formula: see text]g/min). According to the findings, the maximum erosion rate ([Formula: see text][Formula: see text]g/g) was found at a flow velocity of 200[Formula: see text]m/s and 30∘impact angle with a discharge rate of 2.5[Formula: see text]g/min. While the minimal erosion rate was observed at a low velocity of 150[Formula: see text]m/s, 90∘impact angle, and 5[Formula: see text]g/min discharge rate. Electrochemical polarization studies were carried out on the eroded specimens using a corrosive solution containing 3.5% NaCl. Corrosion potentials and current densities were estimated from polarization graphs using the Tafel extrapolation method. The erosion–corrosion properties of the samples were subjected to metallurgical characterization to evaluate the influence of nichrome plasma coatings to assess the potential causes of failure. The grey relational analysis (GRA) was further used for improving the erosion–corrosion process parameters and found the optimum solution as flow velocity of 150[Formula: see text]m/s, 30∘impact angle with a discharge rate of 5[Formula: see text]g/min. The validation test confirmed an increase of 20–30% in grade when using the optimum process parameters.

Li ion transport properties of amorphous/crystalline Li-La-Zr-Nb-O solid electrolyte thick films prepared by suspension plasma spraying

Amorphous Li-La-Zr-O films are considered very attractive as a solid-state electrolyte in future batteries due to their low processing temperatures and resistance to Li-dendrite formation. The knowledge of amorphous Li-La-Zr-O phases is limited and thick films and bulk samples of amorphous Li-La-Zr-O have yet to be explored. Only thin film forms (~0.5 μm) of these amorphous Li-La-Zr-O phases have been prepared. In this work, we investigated the Li-ion transport properties of amorphous/crystalline mixtures of Li-La-Zr-Nb-O thick films (30 to 55 μm) prepared by the suspension plasma spray process. The process was manipulated to alter the amorphous Li-La-Zr-Nb-O content in the as-deposited films. Properties of the films that contained mostly amorphous Li-La-Zr-Nb-O (~76 wt%) were compared vs. mostly cubic Li garnet-type oxide (~55 wt%). The latter showed Li-ion transport properties that were similar to previously reported properties of cubic Li-garnet type oxides whereas the amorphous Li-La-Zr-Nb-O films exhibited significantly different properties. Their AC conductivity spectra show a Jonscher power law (JPL) behavior with the dimensionless exponent of ~0.92 that is followed by superlinear power law (SLPL) behavior with the dimensionless exponent of ~1.65 in the high frequency regime. These behaviors have not been reported earlier for the amorphous Li-La-Zr-Nb-O phases. Both of the JPL and SLPL behaviors have thermally activated characteristic with the activation energies of 0.76 eV and 0.64 eV, respectively. A lower value of ~0.45 eV was evaluated for the activation energy by solid-state 7Li NMR spectroscopy. The effect of temperature on the Li-ion dynamic process was studied by scaling the conductivity spectra and it was found to be temperature independent.

Plasma sprayed fluoride and zinc doped hydroxyapatite coated titanium for load-bearing implants

Titanium (Ti) alloys show excellent fatigue and corrosion resistance, high strength to weight ratio, and no toxicity; however, poor osseointegration ability of Ti may lead to implant loosening in vivo. Plasma spraying of hydroxyapatite [HA, Ca10 (PO4)6 (OH)2] coating on Ti surfaces is commercially used to enhance osseointegration and the long-term stability of these implants. The biological properties of HA can be improved with the addition of both cationic and anionic dopants, such as zinc ions (Zn2+) and fluoride (F−). However, the hygroscopic nature of fluoride restricts its utilization in the radiofrequency (RF) plasma spray process. In addition, the amount of doping needs to be optimized to ensure cytocompatibility. We have fabricated zinc and fluoride doped HA-coated Ti6Al4V (Ti64) to mitigate these challenges using compositional and parametric optimizations. The RF induction plasma spraying method is utilized to prepare the coatings. Multiple parametric optimizations with amplitude and frequency during the processing result in coating thicknesses between 80 and 145 μm. No adverse effects on the adhesion properties of the coating are noticed because of doping. The antibacterial efficacy of each composition is tested against S. aureus for 24, 48, and 72 h, and showed that the addition of zinc oxide and calcium fluoride to HA leads to nearly 70 % higher antibacterial efficacy than pure HA-coated samples. The addition of osteogenic Zn2+and F− leads to 1.5 times higher osteoblast viability for the doped samples than pure HA-coated samples after 7-days of cell culture. Zn2+ and F− doped HA-coated Ti64 with simultaneous improvements in anti-bacterial efficacy and in vitro biocompatibility can find application in load-bearing implants, particularly in revision surgeries and immune-compromised patients.

Porous thermal barrier coatings for enhancing the efficiency of internal combustion engines

Internal combustion engines have a key role in the social and economic advancement of modern society but also a significant contribution to greenhouse gas emissions. For these engines, to preserve their role, a higher efficiency, that dramatically reduces the environmental impact, is necessary. To achieve increased engine efficiency, a technical solution is to lower the heat losses in the combustion chamber. Among them, the heat losses to the pistons are the preferential route, due to their extensive impact on fuel consumption. In this paper, porous thermal barrier coatings with large pores were applied to the pistons of diesel engines to improve engine efficiency. Atmospheric Plasma Spray (APS) process and porosity former TBC feedstock were employed to obtain high porosity coatings with large pores. Scanning Electron Microscopy (SEM) was utilized to investigate the microstructure of the coating in coupons and pistons. The optical properties of the coatings were explored with two methods: the spectral normal hemispherical reflectivity at room temperature (SNHRRT) and spectral normal emissivity at high temperature (SNEHT). The coatings’ behavior under thermal cyclic conditions was assessed by Flame Rig Test. Microstructure analysis was also performed before and after the test to identify the failure mechanisms. The engine efficiency was evaluated by measuring the Indicated Specific Fuel Consumption (ISFC) in a single-cylinder engine test. The results showed that porous coating with large pores combined with a higher emissivity can withstand the engine environment well and have the potential to provide enhancements in engine efficiency.

Effect of Nb and Mo Addition on the Microstructure and Wear Behavior of Fe-Cr-B Based Metamorphic Alloy Coating Layer Manufactured by Plasma Spray Process

Effect of Nb and Mo Addition on the Microstructure and Wear Behavior of Fe-Cr-B Based Metamorphic Alloy Coating Layer Manufactured by Plasma Spray Process

Multi-Layers Composite Plasma Coatings Based on Oxide Ceramics and M-Croll

The paper considers the influence of the parameters of the plasma spraying process on the technological characteristics of multilayer coatings based on nickel-chromium, nickel-chromium-aluminum-yttrium materials, oxide ceramics, intended for operation at high temperature and additional dynamic loads. The design of plasma coatings during their application (with subsequent high-energy processing) under such conditions requires a comprehensive solution – both the use of high-quality powder ingredients and the optimization of technological parameters. The plasma process of applying powder materials has been improved to obtain the maximum values of their utilization factors. The technological characteristics that affect the properties of plasma coatings are optimized, namely: the flow rates of the plasma-forming and materials-transporting gases, the flow rate of supplied powder materials, the current and voltage of the electric arc of the plasma torch, the distance from the plasma torch nozzle exit to the substrate. The paper presents the results of studies of the structure of coatings, performed using scanning electron microscopy. Their analysis has made it possible to form general regularities obtained by the action of radiation of compression plasma flows on coatings formed by air plasma. The considered structures are created using the processes of melting, compaction and high-speed cooling of plasma coatings. The main optimization indicators are the maximum local compaction and spillage of the obtained compositions with the absence of defects and destruction from the impact of compression plasma flows. The main effect during the action of radiation of a compression plasma flow on previously formed coatings is thermal. It contributes heating of the near-surface layer. When the coating is exposed to radiation of compression plasma flows, a remelted layer of oxides with a thickness of about 12–15 µm is created, smoothing the relief of the formed surface and creating a network of cracks on the surface, diverging into the depth of the coating. The liquid-phase processes occurring in the molten phase of the near-surface layers after exposure to compression plasma radiation change the structure of the layers and contribute to the modification of their mechanical properties. By smoothing the surface, increasing the density of the surface crystallized layer and minimizing macro-defects – pores or macrocracks – the mechanical characteristics of the coatings increase.

Oxidation inhibition behaviors of environmental barrier coatings with a Si-Yb2SiO5 mixture layer for SiCf/SiC composites at 1300 °C

Atmospheric plasma spraying (APS) process was employed to produce four-layer Si/Si-Yb2SiO5/Yb2SiO5/LaMgAl11O19 environmental barrier coatings (EBCs) for SiCf/SiC composites with SiC sealing layer. The bending strength of the specimens after isothermal oxidation was investigated. The specimens with EBCs especially thanks to the Si-Yb2SiO5 mixture layer showed a high bending strength retention rate with “psesudo-plastic” fracture. The Si-Yb2SiO5 mixture layer could remarkably enhance the oxidation resistance and also prolonged the life of the EBCs. Such obvious improvements in the Si-Yb2SiO5 mixture layer were attributed to that Yb2SiO5 reacted with TGO (SiO2) to in-situ form a dense Yb2Si2O7 layer, which was conducive to control the thickness of the TGO and prevent the prolongation of the cracks.

A novel reverse-polarity plasma torch with extended hot-wall nozzle for atmospheric plasma spraying of dense yttria-stabilized zirconia coatings

Due to the high heating temperature and low cost, atmospheric plasma spraying (APS) has been widely used in the preparation of ceramic coatings, but its coatings are normally formed by the stacked splats from fully or partially melted feedstock particles, which inevitably leads to some pores, unbonded interfaces or cracks. Thus, in this paper, a novel atmospheric plasma spraying technique using a reverse-polarity plasma torch (RPT) with extended hot-wall nozzle was proposed to fully melt and accelerate feedstock particles for the preparation of dense YSZ ceramic coatings. Firstly, the RPT spray system was designed in detail, and its main electro-thermal characteristics were experimentally studied. The results showed that the RPT exhibited higher arc voltage, thermal efficiency and lower arc voltage fluctuation than that of traditional rod-cathode/normal-polarity plasma torches (NPT) at the similar output power. Secondly, a numerical simulate was carried out to reveal the effect of the extended hot-wall nozzle on the temperature and velocity distributions of the plasma jet. The results showed that the extended hot-wall nozzle remarkably extended the high-temperature and high-velocity region of the plasma jet from the RPT exit to the downstream. Finally, the dense and uniform YSZ coatings with a porosity of about 5.3% were successfully prepared by the RPT with extended hot-wall nozzle. The results showed that the YSZ coating exhibited denser microstructure and fewer defects than that of the coating prepared by traditional APS process. Meanwhile, the hardness and Young's modulus of the YSZ coating were 11.9 ± 1.4 GPa and 197.9 ± 29.4 GPa, respectively, which were relatively higher than that of the coating prepared by traditional APS process, and were very close to that of the coating prepared by very low-pressure plasma spraying (VLPPS) process.

Synthesis of In Situ ZrB2-SiC-ZrC Coating on ZrC-SiC Substrate by Reactive Plasma Spraying.

In situ synthesis feasibility of ZrB2-SiC-ZrC composite coatings on ZrC ceramics by reactive plasma spraying (RPS) was investigated. To help to understand the phase evolution during plasma spraying process, reaction behavior in the ZrH2-Si-B4C system was explored carefully by differential scanning calorimetry. The results indicated that the phase transformation sequence in the ZrH2-Si-B4C system could be described as ZrH1.66, Zr3O, ZrC, ZrB2, Zr2Si, ZrSi, and SiC. The prior formation of ZrC was due to high diffusion rate of C atoms from B4C. ZrB2 was produced above 1100 °C. As the temperature increased, SiC were finally formed by the reaction of ZrC with ZrSi and B4C. The RPS composite coatings mainly consisted of ZrB2, SiC, and ZrC phases, except for a small fraction of ZrO2 phase. The microstructural characterization exhibited more dense melted splats, which appears to increase gradually with the increase in spraying currents and distances. The coatings had typical lamellar structure and adhered to the substrate well. The microhardness values were higher than 1000 HV1, but there were few variations with varying spraying currents and distances.

Impact of post-heat-treatment on the surface-roughness, residual stresses, and micromorphology characteristics of plasma-sprayed pure hydroxyapatite and 7%-Aloxite reinforced hydroxyapatite coatings deposited on titanium alloy-based biomedical implants

The biocompatible hydroxylapatite (Ca10(PO4)6(OH)2) (HA) coating is usually depositing on the titanium substrate to enhance the healing process of implant and to isolate it from the harsh body environment. However, poor mechanical properties of HA restrict its usage for orthopedic applications like hip and knee joints which have to bear the load. The biocompatibility is provided by HA and mechanical strength by the addition of reinforce with HA. Thermal post treatments have been mostly utilized to enhance the morphological and physicomechanical characteristics of as-deposition coatings. In the present research, the emphasis has been laid to analyze the outcome of thermal-processing on phases of hydroxyapatite in coatings developed by plasma spraying process. The surface-morphology of as-sprayed and thermally-processed, HA coated samples was studied using Scanning electron microscope (S.E.M.), Elemental-mapping, X-ray diffraction analysis (X.R.D.), and Fourier-transform infrared (F.T.-I.R.) spectroscopy techniques. The outcomes achieved from the X.R.D. analysis of the hydroxylapatite-coated samples after thermal-treatment reveal the formation of crystalline structure at 750 °C with some traces of CaO. Moreover, when the heat treatment was further done at 950 °C, the unwanted CaO was totally eliminated and coating with crystalline structure was obtained. No substrate element is visible in the X-ray mapping of coatings. The presence of ultrafine particles was observed on both substrates after the heat treatment of coatings at specified temperatures for 2hr in air. These ultrafine particles have the capability to bond with the bone and also helps for bone in-growth on their surfaces.

Cyclic Oxidation Properties of the Nanocrystalline AlCrFeCoNi High-Entropy Alloy Coatings Applied by the Atmospheric Plasma Spraying Technique

Microcrystalline and nanocrystalline AlCrFeCoNi high-entropy alloy (HEA) coatings were applied on Inconel 718 superalloy using the atmospheric plasma spraying (APS) process. The high-temperature oxidation behavior of the microcrystalline and nanocrystalline AlCrFeCoNi HEA-coated superalloy was examined at 1100 °C under the air atmosphere for 50 cycles under cyclic heating and cooling (1 h for each cycle). The oxidation kinetics of both nanocrystalline- and microcrystalline-coated superalloys were accordingly analyzed by weight change measurements. We noted that the uncoated and coated samples followed the parabolic rate law of the oxidation. X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM), energy dispersive X-ray analysis (EDS), elemental mapping and X-ray photoelectron spectroscopy (XPS) were used to analyze the oxidized coated and uncoated samples. In the HEA-coated superalloy, Fe, Ni, Co and Al were oxidized in the inter-splat region, whereas the splats, which consisted mainly of Ni and Cr, remained unoxidized. Due to the formation of compact and adhesive thin NiO, CoO oxides and spinels together with the Al2O3 oxide scale on the surface of the coating during oxidation, the developed nanocrystalline HEA coating showed better oxidation resistance compared with the microcrystalline HEA coating.

Fabrication of Titanium Coatings for Medical Device Applications

Titanium is widely used for medical purposes. It related to bone repair because of its favorable mechanical properties and biocompatible ability to osseointegrate in host bone tissue. A good and lasting connection of the implant with the bone tissue is possible when there are sufficient conditions for the bone to grow into the pores of the material, therefore the use of a porous titanium coating may be helpful in solving this problem. In this paper, shrouded plasma spray is used to produce low oxide containing titanium coatings and lower the cost as titanium is a very reactive metal at high temperatures. A solid conical shroud was designed for plasma spray. The titanium coatings were assessed by scanning electron microscopy and energy dispersive X-ray spectroscopy. An analysis in microstructure had been carried out. The results showed that the shroud attachment played an important role in protecting the titanium particles in flight during the process of plasma spraying. An enhanced microstructure with moderate porosity in the titanium coatings plasma sprayed with the shroud was observed. The reduction in air entrainment with the shroud resulted in a good heating of the particles. The plasma-sprayed titanium coating was mainly composed of α-Ti with a low quantity of TiO.

Microstructural and in-vitro characteristics of functional calcium silicate topcoat on hydroxyapatite coating for bio-implant applications.

The delayed tissue-implant interactions in metallic implants coated with hydroxyapatite (HA) paved the way for the development of alternative bioactive coatings. In this study, bi-layered functional gradient (HA-CS) coating was formulated by the atmospheric plasma spray (APS) process on Ti6Al4V alloy. The HA layer was applied at the metal interface to ensure long-term stability, while the calcium silicate (CS) outer layer was applied to achieve fast tissue-implant interactions. Moreover, single-layered HA and CS coating were also formulated for comparative analysis. The phase compositions, coating microstructure, chemical properties, microhardness, porosity, surface roughness, and in-vitro bioactivity were investigated. The CS top layer showed high porosity and surface roughness with respect to the inner HA layer, which constitutes an optimum microstructure to promote bioactivity. The microhardness of the outer CS layer of HA-CS was 520.3 ± 80.8 HV, while the corresponding value for the inner HA layer was 291.7 ± 45.7 HV. HA-CS and CS coatings demonstrated higher in-vitro bioactivity compared to HA coating. On the contrary, HA coating (3.76 mpy) displayed better corrosion resistance than the HA-CS (4.17 mpy) and CS coatings (4.34 mpy). The in-vitro results indicated that the HA-CS coating could promote the healthy development of osteoblast-like MG-63.

Hot corrosion behavior of hybrid double-layered LZ/LZC + YSZ thermal barrier coatings made using powder and solution precursor feedstock

Lanthanum zirconate (La2Zr2O7; LZ) and cerium doped lanthanum zirconate (La2(Zr0.7Ce0.3)2O7; LZC) has gained immense attention as thermal barrier coating (TBC) materials because of their superior thermophysical properties, high-temperature phase stability and chemical inertness than yttria-stabilized zirconia (YSZ). In the present study, LZ and LZC double-layered TBCs are prepared by solution precursor plasma spray process (SPPS) as a top layer over the atmospheric plasma sprayed YSZ coatings, and their hot corrosion behavior is studied. The as-deposited SPPS coatings exhibited single phases, and the microstructural morphologies reveal a hierarchically structured surface with vertically cracked microstructure. Exposure to the high temperature corrosion process results in damage of the morphology and microstructure within the SPPS layer by forming lanthanum vanadate (LaVO4) and lanthanum cerium vanadate ((LaCe)VO4) in LZ and LZC coatings, respectively, while leaching out zirconia (ZrO2). In the case of conventional YSZ, the corrosive salts infiltrate entirely through the coating and result in complete densification and associated phase changes. While combining the above aspects, the hybrid double-layered architecture of LZ/YSZ and LZC/YSZ coatings can be beneficial to protect the underlying YSZ layer against the detrimental infiltration of molten corrosive salt.

Columnar-structured thermal barrier coatings deposited via the water-based suspension plasma spray process

Suspension plasma spray (SPS) has been developed as a rapid, facile and cost-effective process to deposit columnar-structured thermal barrier coatings (TBCs). In contrast to the most commonly used ethanol-based suspensions, water-based suspensions have not been used in the SPS process to deposit columnar-structured TBCs due to their high surface tension, although they are much cheaper and safer. In this work, a new water-based SPS process was prepared by adding surfactant to lower the surface tension. The optimum content of dispersant and surfactant added to the suspension was determined via measurements of viscosity, particle size, surface tension, contact angles, and atomized droplet size. Coatings deposited using suspensions with and without surfactant showed typical columnar-structured microstructures and vertically cracked microstructures, respectively. The coatings deposited using suspensions with surfactant also showed evolution from columnar-structured microstructures to mixed microstructures of columns and cracks, and to homogeneous microstructures with the increase in standoff distance. The formation of different coating microstructures was correlated to the size of droplets after aerodynamic breakup and the Stokes number of in-flight particles. The new water-based suspension together with the water-based SPS process show great potential to be a cheap and effective alternative to the ethanol-based SPS process.

Effect of CMAS viscosity on the infiltration depth in thermal barrier coatings of different microstructures

Calcium magnesium aluminum silicate (CMAS) is one of the leading concerns for the gas turbine industry. The effects of CMAS viscosity and the coating microstructure on CMAS infiltration depth were explored by conducting a time dependent interaction study. Three CMAS compositions were used from literature, and their viscosities predicted through FactSage viscosity module were drastically different. The interaction was carried out on three different TBCs synthesized using the solution precursor plasma spray process (SPPS): two of the TBCs were made of yttrium aluminum garnet (YAG) having different microstructures that promote different modes of CMAS infiltration, and one TBC was made of gadolinium zirconate (GZO). All samples had stress relieving vertical cracks and different intensities of horizontally banded porosity, (inter pass boundaries IPBs). A concentration of 100 mg/cm2 of CMAS was applied on the TBCs which were then subjected to a 5-minute interaction at 1300 °C. Samples were analyzed using scanning electron microscopy (SEM), electron dispersive X-ray spectroscopy (EDXS), and transmission electron microscopy (TEM). Low viscosity CMAS readily penetrated the TBCs while more viscous CMAS showed less penetration. The depth of CMAS infiltration depended on the coating microstructure. In the YAG with IPBs, the CMAS spread horizontally in the IPBs before infiltrating deeper, resulting in reduced infiltration depth compared to other samples in spite of having wider vertical cracks. TEM and EDXS analysis were performed to investigate the phases present in the CMAS-TBC interaction region in YAG. Two regions were chosen, the top TBC surface in direct contact with the sea of CMAS, and the region at the CMAS penetration ended within the coating. The results showed that no secondary phases like apatite were observed in YAG, thus it can be concluded that the arrest of CMAS happened solely because of CMAS viscosity and the short infiltration time.

Computational fluid dynamics evaluation of conditions before impact of particles in plasma spraying process

Plasma Spraying is one of the most sophisticated and versatile thermal spray techniques. In Plasma Spraying, powdered material is injected into a plasma jet, which is generated from a plasma torch. Upon contact with the plasma jet, the particles are melted and propelled forward onto a substrate to form an adherent coating which modifies the properties of the substrate. The modifications to the substrate can, for example, increase its resistance to other extreme operating conditions such as wear, abrasion, and corrosion. However, the phenomena governing the formation of the plasma jet inside the plasma torch and its subsequent interaction with injected particles are not fully understood. This paper provides a detailed report on steps taken for the development of a comprehensive numerical model to simulate plasma jet development inside a direct current plasma torch. The heat flow and mass exchange of ionized gas with injected solid particles were followed in three dimensions by using a Computational Fluid Dynamics (CFD) method. A cylindrical energy source term which was defined as an increasing linear function dependent on time as a variable, was included to reproduce the effects of an electric arc on the gas flow. For optimization purposes, it was sought to investigate the effects of the particles’ injection angle and inlet velocity, as well as the effects of particle size distribution on the particle temperature and velocity histories.

Performance analysis of plasma spray Ni60CuMo coatings on a ZL109 via a back propagation neural network model

Plasma spray coating properties frequently depend -to a great extent- on the spray parameters. However, it is difficult to analyze and obtain a comprehensive model of the entire plasma spray process due to the complex chemical and thermodynamic reactions that take place during the process. In this study, Ni60CuMo coatings were prepared on ZL109 substrates. A Back Propagation (BP) Neural Network model in the artificial neural network was used to predict the change in bonding strength, microhardness, and porosity of the coatings under different spraying distances, spraying powers, and powder feeding rates. The results show that the R-value of the trained network training is 0.8828. Comparison of experimental and predicted results reveals that both show similar trends, which verifies that the BP model can effectively predict the properties of Ni-based coatings.

Investigation on Hot Corrosion Behaviour of Inconel 625 and Incoloy 800H Superalloys with YSZ‐Thermal Barrier Coating Under High‐Temperature Environment for Bioreactor Applications

Thermal energy storage is one of the promising technologies in the modern era for balancing the peak power demand without emitting much emission. Molten‐salt technology plays a dominant role among the varieties of thermal energy storage systems. The difficulty in storing the molten‐salt technology requires a storage material with high temperature, corrosion, and oxidation resistance properties. The nickel‐based superalloys such as Inconel 625 and Incoloy 800H possess the desired properties to be used as a storage material for the molten salts. In this present work, the Incoloy 800H and Inconel 625 superalloy specimens were taken up for investigation. The specimens were coated with yttria‐stabilized zirconia as a thermal barrier coating using a plasma spray process. The sodium chloride and potassium chloride molten salts with a weight fraction of 7 : 3 have been taken with both uncoated and YSZ‐coated specimens, and specimens were heated up to 1000°C approximately. The specimens were heated for different hours such as 8, 12, and 16 hours, respectively. The increase in heating time also results in the increase in the tensile property of the specimens. The mechanical testing, such as tensile test and hardness test, was performed to comprehend the mechanical properties. Scanning electron microscope images and X‐ray diffraction analysis were made to study the microstructural properties and the corrosion resistance property. From the test results, YSZ‐coated specimens possess high corrosion resistance and high mechanical strength compared to the uncoated specimens.

Investigate the corrosion properties of stellite coated on AZ91D alloy by plasma spray technique

Stellite alloys are primarily preferred in various component manufacturing industries due to its magnificent mechanical and electrochemical properties. The stellite powder is deposited over the materials by various thermal spray methods in industries. This research proposed investigating the microstructure and corrosion properties of stellite powder that is deposited on an AZ91D magnesium alloy substrate by atmospheric plasma spraying process. The SEM, optical microscopy, and atomic force microscopy are typical of the coatings. Immersion experiments in sodium chloride conditions are conducted at varying pH levels, chloride ion concentration, and exposure time. In addition, XRD examined the phase change properties of the powder and sprayed condition of coatings along with corrosion testing. The corrosion experiments were conducted to establish several regression models based on the central composite design and the response sur-face process. The accuracy of the regression models was sufficient to allow correlations between input parameters and responses through variance analysis. It was found that the pH value significantly influences the corrosion behaviour of stellite coatings followed by other parameters such as chloride ion concentration and exposure time, even in corrosion tests, plasma-sprayed coatings performed better.