Journal of Advanced Materials and Technologies

Journal of Advanced Materials and Technologies

Effect of Precursor Concentration on the Microstructure of Aluminum Oxide Coating Made through the Solution Precursor Plasma Spray Process

Document Type : Original Reaearch Article

Authors
Amir Kebriyaei 1
Mohammad Reza Rahimipour 2
Mansour Razavi 3
Atabak Alizadeh Herfati 4
1 Ph. D. Student, Department of Ceramic, Materials and Energy Research Center (MERC), MeshkinDasht, Alborz, Iran
2 Professor, Department of Ceramic, Materials and Energy Research Center (MERC), MeshkinDasht, Alborz, Iran
3 Associate Professor, Department of Ceramic, Materials and Energy Research Center (MERC), MeshkinDasht, Alborz, Iran
4 M. Sc., Materials and Metallurgy Engineerin College, University of Tehran, Tehran, Tehran, Iran
10.30501/jamt.2021.264619.1147
Abstract
In this research, the equipment required to produce ceramic coatings based on Solution Precursor Plasma Spray (SPPS) method was first identified and manufactured by exploring the relevant sources and contained information. Then, aluminum oxide coating was applied to the substrate with MCrAlY bond coat using the set-up. Further, a solution of aluminum sulphate with the concentrations of 0.5 and 1 molar was prepared and used as a precursor injected into the plasma plume in order to evaluate the effect of the precursor concentration on the coating microstructure. The results revealed that the alumina coating obtained from the more diluted precursor had a more porous structure than its counterpart, and its microstructure contained some bubble-like fractured shells as well as small spherical particles. However, the coating obtained from the precursor with higher concentration was found to be denser mainly due to the phenomenon occurring during the deposition through the SPPS process. The XRD analysis yielded similar results for both coatings where the α-Al2O3 was the predominant phase in the coating.
Keywords
SPPS
Set Up
Alumina
Fractured Shells
Precursor
Subjects
  1. Pawlowski, L., "The relationship between structure and dielectric properties in plasma-sprayed alumina coatings", Surface and Coatings Technology, Vol. 35, No. 3-4, (1988), 285-298. https://doi.org/10.1016/0257-8972(88)90042-4
  2. Li, C. J., Yang, G. J., Ohmori, A., "Relationship between particle erosion and lamellar microstructure for plasma-sprayed alumina coatings", Wear, Vol. 260, No. 11-12, (2006), 1166-1172. https://doi.org/10.1016/j.wear.2005.07.006
  3. Stahr, C. C., Saaro, S., Berger, L. M., Dubský, J., Neufuss, K., Herrmann, M., "Dependence of the stabilization of α-alumina on the spray process", Journal of Thermal Spray Technology, Vol. 16, No. 5-6, (2007), 822-830. https://doi.org/10.1007/s11666-007-9107-7
  4. McPherson, R., "On the formation of thermally sprayed alumina coatings", Journal of Materials Science, 15, No. 12, (1980), 3141-3149. https://doi.org/10.1007/BF00550387
  5. Niemi, K., Vuoristo, P., Mäntylä, T., Lugscheider, E., Knuuttila, J., Jungklaus, , "Wear characteristics of oxide coatings deposited by plasma spraying, high power plasma spraying and detonation gun spraying", In Advances of Thermal Scince and Technology, Proceedings of The 8th National Thermal Spray Conference, ASM International, Materials Park, Ohio, U.S., (1995), 645-650. https://www.osti.gov/biblio/379581
  6. Krishnan, R., Dash, S., Kesavamoorthy, R., Babu Rao, C. B., Tyagi, A. K., Raj, B., "Laser surface modification and characterization of air plasma sprayed alumina coatings", Surface and Coatings Technology, 200, No. 8, (2006), 2791-2799. https://doi.org/10.1016/j.surfcoat.2005.05.002
  7. Jun, B. S., Lee, S. J., Messing G. L., "Synthesis of nano-scaled a-Al2O3 particles by combustion spray pyrolysis", Key Engineering Materials, 317-318, (2006), 207-210. https://doi.org/10.4028/www.scientific.net/KEM.317-318.207
  8. Jordan, E. H., Jiang, C., Gell, M., "The solution precursor plasma spray (SPPS) process: A review with energy considerations", Journal of Thermal Spray Technology, 24, No. 7, (2015), 1153-1165. https://doi.org/10.1007/s11666-015-0272-9
  9. Gell, M., Jordan, E. H., Teicholz, M., Cetegen, B. M., Padture, N. P., Xie, L., Chen, D., Ma, X., Roth, J., "Thermal barrier coatings made by the solution precursor plasma spray process", Journal of Thermal Spray Technology, Vol. 17, No. 1, (2008), 124-135. https://doi.org/10.1007/s11666-007-9141-5
  10. Xie, L., Chen, D., Jordan, E. H., Ozturk, A., Wu, F., Ma, X., Cetegen, B. M., Gell, M., "Formation of vertical cracks in solution- precursor plasma-sprayed thermal barrier coatings", Surface and Coatings Technology, Vol. 201, No. 3-4, (2006), 1058-1064. https://doi.org/10.1016/j.surfcoat.2006.01.020
  11. Moreau, C., Bisson, J. F., Lima, R. S., Marple, B. R., "Diagnostics for advanced materials processing by plasma spraying", Journal Pure and Applied Chemistry, Vol. 77, No. 2, (2001), 443-462. https://doi.org/10.1351/pac200577020443
  12. Ma, X., Wu, F., Roth, J., Gell, M., Jordan, E. H., "Low thermal conductivity thermal barrier coating deposited by the solution plasma spray process", Surface and Coatings Technology, Vol. 201, No. 7, (2006), 4447-4452. https://doi.org/10.1016/j.surfcoat.2006.08.095
  13. Chen, D., Jordan, E. H., Renfro, M. W., Gell, M., "Dy: YAG phosphor coating using the solution precursor plasma spray process", Journal of the American Ceramic Society, Vol. 92, No. 1, (2009), 268-271. https://doi.org/10.1111/j.1551-2916.2008.02846.x
  14. Puranen, J., Laakso, J., Kylmälahti, M., Vuoristo, P., "Characterization of high-velocity solution precursor flame-sprayed manganese cobalt oxide spinel coatings for metallic SOFC interconnectors", Journal of Thermal Spray Technology, Vol. 22, No. 5, (2013), 622-630. https://doi.org/10.1007/s11666-013-9922-y
  15. Candidato Jr, R. T., Sokołowski, P., Pawłowski, L., Denoirjean, A., "Preliminary study of hydroxyapatite coatings synthesis using solution precursor plasma spraying", Surface & Coatings Technology, Vol. 277, (2015) 242-250. http://dx.doi.org/10.1016/j.surfcoat.2015.07.046
  16. Xu, P., Coyle, T. W., Pershin, L., Mostaghimi, J., "Fabrication of micro-/nano-structured superhydrophobic ceramic coating with reversible wettability via a novel solution precursor vacuum plasma spray process", Materials & Design, Vol. 160, (2018), 974-984. https://doi.org/10.1016/j.matdes.2018.10.015
  17. Jadhav, A., Padture, N. P., Wu, F., Jordan, E. H., Gell, M., "Thick ceramic thermal barrier coatings with high durability deposited using solution-precursor plasma spray", Materials Science and Engineering: A, Vol. 405, No. 1-2, (2005), 313-320. https://doi.org/10.1016/j.msea.2005.06.023
  18. Çılgı, G., Cetişli, H., "Thermal decomposition kinetics of aluminum sulfate hydrate", Journal of Thermal Analysis and Calorimetry, Vol. 98, No. 3, (2009), 855-861. https://doi.org/10.1007/s10973-009-0389-5
  19. Chen, D., Jordan, E. H., Gell, M., "Effect of solution concentration on splat formation and coating microstructure using the solution precursor plasma spray process", Surface & Coatings Technology, 202, No. 10, (2008), 2132-2138. https://doi.org/10.1016/j.surfcoat.2007.08.077

 

 

  • Receive Date 04 January 2021
  • Revise Date 04 April 2021
  • Accept Date 11 April 2021