Plasma Spraying Technology Research Articles

Effect of heat treatment on the interfacial element diffusion and hardness of FeCoNiCrAl high-entropy alloy coatings

FeCoNiCrAl high-entropy alloy (HEA) coatings have here been prepared on Q235 steel by using the plasma spraying technology. The effects of heat treatment (300 °C, 400 °C, and 500 °C) on the coating phase, surface and cross section morphologies, surface Brinell hardness (HRB), cross section Vickers hardness (HV), and element diffusion at the coating interface, were then investigated. The distribution of pores, cracks, and unmelted particles on the surface of the coating was analyzed by scanning electron microscopy (SEM). The results showed that the BCC crystalline structure of the HEA coating did not change significantly after heat treatment at 300 °C, 400 °C, and 500 °C. In addition, the bonding between the coating and the matrix interface became significantly improved, and the cracks at the coating interface were eliminated. New oxides that filled the pores and cracks inside and at the interface of the coating were also observed as the temperature and holding time increased. Furthermore, the surface hardness of the Q235 steel was reduced as a result of the spray coating. However, this surface hardness was increased to HRB 85 (or even more) after heat treatment. Compared with the other samples, the coating sample that was heat-treated at 500 °C showed the best strength.

Preparation and Characterization of Al2O3/h-BN Composite Coatings by Atmospheric Plasma Spraying (APS)

To improve the adhesion strength of polymer functional films, corona treatment is required. Corona rollers are key components for corona treatment, which are used in high-voltage electric fields for a long time. In this work, in order to improve electrical insulation, arc resistance, wear resistance, and chemical stability, a coating is usually sprayed on the surface of the corona roller. Al2O3/h-BN composite coatings are prepared on the surface substrate of a corona roller (20 steel) by atmospheric plasma spraying (APS) technology. Scanning Electron Microscope (SEM) and X-ray diffraction (XRD) analysis showed that the Al2O3/h-BN composite coating had a layered structure and compactness. Two kinds of Al2O3/h-BN composite coatings are prepared under different APS process parameters; the porosities of A coating and B coating are 6.04% and 4.75%, the microhardnesses are 781 ± 0.5 Hv and 840.5 ± 0.5 Hv, and the adhesion strengths are 22.0 MPa and 22.3 MPa, respectively. The A and B volume resistivity of the coatings are 9.29 × 1010 Ω·cm and 3.55 × 1010 Ω·cm, respectively. The volume resistivity and porosity of the coatings are negatively correlated, and they decrease with the increase in spraying current. But for both coatings, volume resistivity is greater than 1 × 1010 Ω cm. These results indicate that the Al2O3/h-BN composite coatings, as a new type of electrode roller coating, satisfy the use requirement. Al2O3/h-BN composite coatings can become the potential for ceramic coatings that have good mechanics and insulation performance.

FeCoNi-Based Alloy Coatings as Low Overpotential Electrocatalysts for Alkaline Water Electrolysis.

Developing efficient, stable and low-cost electrocatalysts is a viable approach to solve the current energy crisis. It is found that increasing the surface area of the electrodes can effectively promote the electrocatalytic efficiency. Herein, the atmospheric plasma spraying (APS) technology was used to prepare FeCoNi-Ni3C alloy coating by adding Ni3C powder to FeCoNi powder with an equal molar ratio. After mechanical mixing, the atomic ratios of Ni3C in the powder are 25 %, 50 %, and 75 %, respectively. The results prove that the pores on the surface of the coating have increased after Ni3C doping, which can provide more active sites in the electrocatalytic process to promote the electrocatalytic reaction. By controlling the proportion of Ni3C, the porosity of the coating surface can be effectively regulated. The results suggested that in 1.0 M KOH electrolyte and 10 mA cm-2, the FeCoNi coating shows an overpotential of 191 and 277 mV for HER and OER, respectively, the HER overpotential of 50 at % Ni3C FeCoNi-Ni3C coating is 105 mV, and the OER overpotential is 212 mV. It is worth noting that the 50 at % Ni3C FeCoNi-Ni3C coating has a low Tafel slope of 45.78 mV dec-1 (HER) and 44 mV dec-1 (OER). Meanwhile, the attenuation of the overpotential of the 50 at % Ni3C FeCoNi-Ni3C coating after the stability test is almost negligible, indicating that the prepared catalyst has excellent electrocatalytic stability. Furthermore, the 50 at.% Ni3C FeCoNi-Ni3C coating catalyst has a low potential of 1.664 V at 10 mA cm-2 in a water-splitting system. This work provids a new idea for designing inexpensive electrocatalysts.

The Study of the Etching Resistance of YOF Coating Deposited by Atmospheric Plasma Spraying in HBr/O2 Plasma

Yttrium oxyfluoride (YOF) coatings with different oxygen content were prepared using atmospheric plasma spraying (APS) technology. The etching resistance of the coatings in HBr/O2 plasma was investigated. Shifts in diffraction peaks of the X-ray diffraction, along with XPS analysis conducted before and after etching, demonstrated that Br ions could replace O and F ions and fill the oxygen vacancies after exposure to HBr/O2 plasma, which is supported by the first-principles calculations. Br ions formed a protective layer on the surface of the YOF coating, slowing down further etching by Br ions. By adjusting the oxygen mass fraction in YOF powder, the oxygen vacancy concentration and Br ion filling were regulated to enhance etching resistance. YOF coatings with 6% oxygen content exhibited improved etching resistance compared to YOF coatings with 3% and 9% oxygen content. This improvement was primarily due to the increased Br ion concentration. These findings provide a new approach for developing coatings with enhanced etching resistance.

Properties of Al0.5CoCrFeNi2Ti High-Entropy Alloy System: From Gas-Atomized Powders to Atmospheric Plasma-Sprayed Coatings

AbstractThe performance of the Al0.5CoCrFeNi2Ti HEA atmospheric plasma-sprayed coating was extended from characterizing the properties of its powder prepared via the gas atomization method. It was observed that the gas-atomized HEA powders possessed a solid solution BCC phase, while a major phase transformation to a FCC-L21 intermetallic phase occurred during the annealing process. The formation of the intermetallic phase resulted in an increase in average hardness from 6.28 to 7.64 GPa after annealing at 900 °C for 1 h. Afterward, HEA powders were applied in the atmospheric plasma spray technology. The phase constitution of Al0.5CoCrFeNi2Ti HEA coatings was investigated by varying powder size and applied current. It was observed that the smaller powder sizes prone to oxidation, whereas higher applied current facilitated the phase transformation from BCC to FCC phase. The nanoindentation test indicated distinct average microhardness values for the interlamellar oxide region, BCC unmelted particle and FCC phase lamellar region, which was measured at 12.35, 8.68 and 5.97 GPa, respectively. As a result, the adjustability of coating hardness was achieved by manipulating the relative phase ratio.

Influence of Plasma Arc Current and Gas Flow on the Structural and Tribological Properties of TiN Coatings Obtained by Plasma Spraying

This study investigates the development of TiN-based coatings using plasma spraying technology, focusing on how plasma arc current and working gas flow rate affect the coatings’ structural-phase composition and mechanical–tribological properties. The research highlights the potential and effectiveness of plasma spraying for TiN coatings. Results from scanning electron microscopy and nanoindentation tests show that the TiN coatings have a dense microstructure with strong adhesion. Tribological testing demonstrated that coatings deposited at a 250 A arc current displayed the lowest coefficient of dry friction and the lowest porosity (2.13%) compared to those deposited at 350 A and 450 A arc currents, which exhibited higher porosity (up to 10.45%).

Structural characteristics and evolution in the crack propagation process of NiCrAlY/YSZ gradient coatings through thermal shock at 900 °C

In this study, four different thicknesses of NiCrAlY/8YSZ gradient coatings were fabricated using atmospheric plasma spraying (APS) technology. The failure behavior and lifetime of coatings were subsequently compared and analyzed through thermal shock experiments. The results revealed a pronounced correlation between the initiation and propagation of internal cracks within the gradient coatings and the thickness of the gradient region at a thermal shock temperature of 900°C. Both horizontal and vertical cracks were observed to propagate and interconnect, with horizontal crack propagation being the primary cause of coating failure. Notably, samples featuring a gradient region thickness of 150μm exhibited superior thermal shock resistance, suggesting promising prospects for enhanced coating durability.

Enhanced Anti-Corrosion and Biological Performance of Plasma-Sprayed Nb/ZrO2/HA Coatings on ZK60 Mg Alloy

Niobium (Nb) and zirconium dioxide (ZrO2) were doped into hydroxyapatite (HA) to fabricate HA-based composite coatings prepared on a ZK60 magnesium alloy by plasma spraying technology to improve anti-corrosion and biocompatibility for clinical applications. The results revealed that the Nb-enriched coating exhibits fewer cracks and pores with a flat surface due to the decreased temperature gradient during spraying, and small needle-like structures can fill the cracks and pores in the ZrO2-contained coating, resulting in a more uniform and dense surface. Compared to coatings with only niobium or zirconium dioxide, the ZrO2/Nb/HA composite coating significantly enhanced the mechanical properties and corrosion resistance of the magnesium alloys. Among all the specimens, the ZrO2/HA coating and ZrO2/Nb/HA coating revealed high surface hardness values (327.73 HV and 293.80 HV, respectively). However, the higher hardness value made the ZrO2/HA coating fragile and more likely to crack, while the ZrO2/Nb/HA coating avoided this shortcoming and exhibited a more comprehensive performance. During immersion tests, the ZrO2/Nb/HA coating exhibited a gradual pH increase and minimal mass loss, and the cytocompatibility test demonstrated promising cellular activity.

A comparison of cold spray, atmospheric plasma spray and high velocity oxy fuel processes for WC-Co coatings deposition through LCA and LCCA

In this study, an environmental and economic assessment of WC-Co coatings deposited by Cold Gas Spray (CGS), Atmospheric Plasma Spray (APS) and High Velocity Oxy Fuel (HVOF) spray technologies is carried out. Using SimaPro LCA software, several environmental impact categories are analyzed to compare their environmental performance. The economic analysis includes capital and operating expenditures. The results have highlighted that all three processes exhibit low environmental impact in terms of CO2 emissions but the performance of the CGS process is heavily influenced by the low deformability of WC-Co, while the APS process is affected by high electricity consumption. In terms of economic analysis, the HVOF process exhibits the best performance, while the CGS process requires most time to deposit the coating, and consequently, it is the process where the workforce component is most significant. These results depend on the fact that CGS might not be the most suitable deposition technique for fabricating WC-Co coatings.

Microstructure and properties of plasma sprayed NbC-Al2O3 composite coatings

Niobium carbide has received widespread attention due to its high melting point, high strength, high chemical stability and high wear resistance, but the current preparation of niobium carbide coatings using plasma spraying technology suffers from low deposition efficiency, poor fusibility of the composite powders, high porosity, and high defects in the coating microstructure. Therefore, the microstructure and properties of NbC-Al2O3 composite coatings prepared by plasma spraying NbC-Al2O3-SiC composite powder and reactive plasma spraying Nb2O5-SiC-Al composite powder were comparatively investigated in this paper. The reaction mechanism of Nb2O5-SiC-Al composite powder during plasma spraying as well as the mechanism of the formation of coatings were analyzed in detail. The results showed that compared with the ex-situ NbC-Al2O3-SiC coating fabricated by plasma spraying, the in-situ Nb2O5-SiC-Al composite coating prepared by reactive plasma spraying had an obvious layer structure, low porosity (5.8%), high hardness (1141 HV0.1), high toughness (22.94 J/m2), and good scratch resistance properties.

Microstructure and properties of Al/FeCoNiCrMo coatings prepared by different plasma spraying currents on carbon fiber reinforced plastic surfaces

Al/FeCoNiCrMo high-entropy alloy (HEA) coatings were prepared on the surface of carbon fiber reinforced plastic using plasma spraying technology. The microstructure of the HEA coatings was characterized under different spraying currents, and the hardness, interfacial bonding, corrosion resistance and friction and wear properties of the coatings were tested. The results showed that with the increase of the current, the unfused particles in the coatings decreased, and the coating porosity and thickness also decreased gradually; the hardness, corrosion resistance and friction and wear resistance properties increased with the increase of the current, in which the maximum hardness was 740.3 HV0.1, and the minimum self-corrosion current was 1.21 × 10−5 A·cm−2, and the minimum volumetric wear rate was 7.66 × 10−5 mm3·N−1·m−1.

Thermal cycling property of the novel Hf6Ta2O17/YSZ TBCs prepared by atmospheric plasma spraying technology

Hf6Ta2O17, with low thermal conductivity, high thermal expansion coefficient, and excellent fracture toughness, was a promising candidate ceramic top coat material of thermal barrier coating (TBC). A novel Hf6Ta2O17/YSZ double ceramic top coat prepared by atmospheric plasma spraying (APS) was applied to study the role of the microstructure and mechanical property on the thermal cycling property at 1200 °C. Results show that the rapid decomposition of Hf6Ta2O17 occurred during the spraying process. As the increased spraying power, more HfO2 phases were observed in the Hf6Ta2O17/YSZ TBCs. Besides, the porosity of the Hf6Ta2O17 ceramic top coat decreased with the increased spraying power, resulting in the elastic modulus of the Hf6Ta2O17 ceramic top coat enhancement. The highest cycles at 1200 °C were obtained for the Hf6Ta2O17/YSZ TBCs with the lowest elastic modulus and least HfO2 phases, and were twice as long as the cycles of the single YSZ TBCs. The chemical reaction between HfO2 and Hf6Ta2O17 might have contributed to the cracking of the Hf6Ta2O17/YSZ TBCs. This work provides a new option for the preparation and development of the ternary oxides by APS.

Effect of TiO2 content on the thermal control properties of Al2O3-xTiO2 composite coatings prepared by supersonic plasma spraying technology

The main challenge faced by spacecraft is the large temperature difference in its operating environment. Thermal control coatings prepared on spacecraft and instrument surfaces are currently the most efficient ways for heat dissipation and control. In this work, Al2O3-xTiO2 composite coatings with different TiO2 contents were prepared on 7075-Al alloy substrate by supersonic plasma spraying technology. The microstructure, phase composition, mechanical properties, thermal control properties, and corrosion resistances of the coatings were investigated. The raw stock feeds were mainly composed of α-Al2O3 and anatase TiO2, but the coatings were mainly γ-Al2O3 and rutile TiO2. The average Vickers microhardness of the coatings decreased from 1198.9 to 810.4 HV0.2 with the increase of TiO2 contents, but the elastic modulus increased from 158.5 to 244.3 GPa. The thermal control properties of the coatings were promoted with the growth of TiO2 contents, and the absorptance increased from 27.1 to 89.2% with the emittance from 83.7 to 86.5%. The corrosion potential and corrosion resistance of the coating gradually increased with TiO2 content due to its gradually improved hydrophobicity. This work broadens the application boundary of Al2O3-xTiO2 composite coating and provides an innovative idea for material selection of thermal control coatings.

Discrepancy evaluation in mechanics and corrosion resistance of reactive plasma sprayed TiN coatings fabricated under different heat treatment

Ceramic coatings have positive feedback to annealing treatment, but improper annealing treatment can also bring disastrous consequences. In this article, a thick TiN coating without a bonding layer was prepared by reactive plasma spraying technology and then subjected to heat treatment at three different temperatures in atmospheric and argon atmospheres. By exploring the hardness, modulus, and corrosion resistance of the coatings, combined with analysis of microstructure, phase composition, and interatomic bonding conditions, it was found that the TiN coating exhibited the lowest porosity after atmospheric heat treated at 500 °C. Meanwhile, it also showed the highest hardness, modulus, and optimal corrosion resistance. After heat treated at 650 °C in the atmosphere, the protective performance of the coating was decreased, but it was still far superior to the as-sprayed coating. The coating after heat treated in the argon atmosphere did not achieve ideal performance. The coating heat treated at 650 °C even exhibited inferior comprehensive performance to the as-sprayed coating. Therefore, it was summarized that the atmospheric environments and the temperature above the phase transition temperature were suitable for obtaining the optimal TiN coating.

Influence of added La2O3 on the microstructure, mechanical properties, and tribocorrosion resistance of TiB2–Ni plasma-sprayed coatings

To enhance the tribocorrosion resistance of 7075-T6 aluminum alloy in deep sea environments, TiB2–Ni coatings with varying La2O3 content were deposited on 7075-T6 aluminum alloy substrates using plasma spray technology. The effects of different La2O3 contents on the organization, structure, and properties of the coatings were analyzed. The results indicated that La2O3 incorporation suppressed brittle phase formation such as Ni3B; 1.0 wt% La2O3 addition reduced Ni3B by 16.9%. The coating's corrosion resistance significantly improved with La2O3 doping - the self-corrosion current density of the 1.0 wt% La2O3-doped coating decreased from 71.2 nA/cm2 to 30.2 nA/cm2.

Study on microstructure and thermal shock resistance of plasma sprayed Cr2O3/8YSZ composite coating

In order to explore the high temperature performance of Cr2O3/8YSZ composite coating, four kinds of Cr2O3/8YSZ composite coatings were prepared on the surface of Q235 steel by using the plasma spraying technology (the content of 8YSZ is 50%, 30%, 20% and 0%, respectively). The morphology of the coating was characterized through thermal field emission scanning electron microscopy, and the distribution of elements in the section of the coating was scanned by using EDS line. The phase composition of the composite coating was analyzed by using X-ray diffractometer, and the surface roughness of the composite coating was measured by using surface profilometer. The microhardness of the coating was measured by using automatic micro-Vickers hardness tester, and the scratch resistance of the coating was compared by using scratch tester. The thermal shock resistance of the coating was tested in Gleeble-3800 thermal physical simulator, and the cross section morphology after thermal shock was observed and analyzed. The results show that when the ratio of Cr2O3 to 8YSZ is 7∶3, the sample coating has good thermal shock resistance due to the deflection effect of 8YSZ on the vertical cracks and the thermal stress release effect of the pores and cracks in the coating.

Study on the performance of GDC electrolytes fabricated by atmospheric plasma spraying and vacuum plasma spraying

For metal-supported solid oxide fuel cells (MS-SOFCs), gadolinium-doped ceria (GDC) is one of the most promising electrolyte materials due to its high ionic conductivity. The plasma spraying technique has unique advantages in the preparation of MS-SOFCs, such as high efficiency, low cost, and low thermal impact on the metal support. However, few studies have been conducted on the preparation of dense GDC electrolytes using plasma spraying technology. In addition, it is not clear whether the composition and Ce valence state of GDC change during the plasma spraying process. In order to investigate this issue, GDC electrolytes were fabricated by atmospheric plasma spraying (APS) and vacuum plasma spraying (VPS) techniques. It is found that the GDC electrolyte fabricated by VPS is denser and has better electrochemical performance. The open circuit voltage and maximum power density of the VPS-cell at 600 °C are 0.90 V and 175.7 mW/cm2, respectively, while those of the APS-cell are 0.86 V and 124.8 mW/cm2, respectively. Moreover, the valence state of Ce4+ in the GDC electrolyte remains unchanged after plasma spraying, while the composition of Ce/Gd changes. This work successfully fabricates GDC electrolytes with qualified performance and provides a reference for further optimizing spraying parameters to prepare high-performance MS-SOFC.

CMAS corrosion resistance of YSZ thermal barrier coatings with Al2O3 and YSZ-Al2O3 protective layers

Molten calcium-magnesium-alumina-silicate (CMAS) corrosion has become a major constraint for the application of YSZ thermal barrier coatings (TBCs). In this paper, Al2O3 and YSZ-Al2O3 protective layers with a thickness of 50 μm were prepared on the surface of 8YSZ TBCs using air plasma spraying technology, and the progressive damage modes of the different TBCs under CMAS exposure were investigated, and the effects of the composition and microstructure of the protective layers on the infiltration and wetting behaviour of CMAS were compared. When the exposure time was shorter, the dense YSZ-Al2O3 had a better impermeability barrier effect. As the interaction time between CMAS and the coating was prolonged, the structure and phase stability of YSZ-Al2O3 were damaged, the thickness was thinned, and Al2O3 had better stability and showed better protective effect. CMAS wettability was mainly related to the roughness of the coating surface, and the wettability was poorer on rough surfaces.

CMAS Corrosion Resistance of Plasma-Sprayed YSZ and Yb2O3-Y2O3-Co-Stabilized ZrO2 Coatings under 39–40 KW Spraying Power

This study uses atmospheric plasma spraying (APS) technology to prepare thermal barrier coatings (TBCs) with yttrium-stabilized zirconia (YSZ) and Yb2O3-Y2O3-co-stabilized ZrO2 (YbYSZ) materials at different spraying powers. It analyzes the differences and changes in the microstructure, thermodynamic properties, and mechanical properties of the TBCs. The CaO-MgO-Al2O3-SiO2 (CMAS) resistance of coatings was tested using thermal cycling-CMAS experiments and isothermal corrosion experiments. Compared to YSZ coatings, YbYSZ coatings have lower thermal conductivity, a higher hardness and elastic modulus, a longer lifetime under thermal cycling-CMAS conditions, and lower penetration and degradation depths. Under thermal cycling-CMAS coupling conditions, the optimal power range for the longest thermal cycling lifetime for both coatings is 39–40 kW. Overall, compared to the YSZ material, the YbYSZ material exhibits superior properties.

Tribological properties of atmospheric plasma sprayed Cr3C2–NiCr/20% nickel-coated graphite self-lubricating coatings

Using atmospheric plasma spraying technology, Cr3C2–NiCr (CN)and Cr3C2–NiCr/20 % Nickel-coated graphite (CG) composite coatings were successfully deposited on 304 stainless steel substrates, with three different spraying distance parameters designed to optimize the experiment. The study investigated the influence of nickel-coated graphite on the structure, hardness, porosity, and friction-wear performance of the composite coatings. Wear mechanisms were investigated based on analyses of morphologies and chemical states of the worn surfaces of the CG composite coatings. Our results demonstrate that the CG coating exhibits lower friction coefficients, ranging from 0.24 to 0.28, than that of the CN coating. The incorporation of nickel-coated graphite leads to formation of a solid-lubricating film at friction interface, lowering friction and wear. What's more, presence of nickel-coated graphite mitigates brittleness of the CN coating, as is deemed important for improving abrasion resistance of the coatings.