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Suspension plasma spray coating of advanced ceramics : thermal barrier applications
\"Suspension Plasma Spray Coating of Advanced Ceramics presents the significance of suspension plasma spray coating of ceramics for thermal barrier applications. It covers suspension formation and optimization in different oxide and non-oxide mixtures and ceramic matrix composites (CMC) of sub-micron and nanosized powders. The book will be useful for professional engineers working in surface modification and researchers studying materials science. This book discusses advanced topics on nanomaterials coatings in monolithic or composite forms as thermal barriers through organic and non-organic based suspensions using high energy plasma spray methods\"-- Provided by publisher.
Book
Plasma Spraying of Ceramic Coating with All Interfaces Bonded Chemically through a Ceramic Bond Coat Thermally Grown on Metal Substrate
Plasma-sprayed ceramic coatings are widely used for corrosion protection of metallic parts in industries. However, conventional ceramic coatings bond to metal substrates mainly through mechanical interlocking, with a tensile adhesion lower than 40 MPa, which limits their high-load applications. In this study, a new strategy to enhance the adhesion of coatings to a level over 100 MPa is proposed through introducing a ceramic bond coat to create chemical bonding throughout all the interfaces within the coating system. The experimental approval is made using titanium (Ti) as a typical substrate and Al
2
O
3
-13TiO
2
(AT13) as a typical coating material. The ceramic bond coat on Ti substrate was introduced by thermal growing under different oxidation conditions. The AT13 coating was deposited at 300 °C which was determined following the critical bonding temperature theory. It is found that the chemical bonding for all interfaces between ceramic layers was achieved by dynamic wetting of spreading molten splats ensured by the critical bonding temperature concept. The tensile test was modified by reducing the effective contact area of AT13 ceramic coatings to the substrate, and the adhesion of the ceramic coating prepared by the new method ranged from 105 to 121 MPa. This study provides a new technological approach for the application of plasma-sprayed ceramic coatings in high-load environments.
Journal Article
Research on thermo-mechanical coupling behavior of plasma-sprayed mullite ceramic coatings on concrete surfaces
This study systematically investigates the thermo-mechanical coupling behavior of plasma-sprayed mullite ceramic coatings on concrete surfaces through integrated finite element simulation and experimental verification. A three-dimensional thermo-mechanical coupling model was developed on the ANSYS Fluent platform to simulate temperature field distribution, residual stress evolution, and their impacts on interfacial bonding strength during the spraying process. Experimental data calibration confirmed the model accuracy with <5% deviation. Results demonstrate that spraying power and stand-off distance critically influence coating temperature gradients. Optimized parameters reduced interfacial residual stress to <50 MPa while decreasing porosity to 8.3%. SEM-EDS and X-CT analyses revealed the correlation between pore distribution and stress concentration. Thermal expansion coefficient mismatch was identified as the primary cause of interfacial delamination. Process optimization enhanced interfacial bonding strength by 38.7%, establishing a reliable predictive model for coating thermo-mechanical performance. The findings provide theoretical guidance for plasma spraying parameter optimization and establish a validated framework for concrete surface protection coating design. This research advances the fundamental understanding of substrate-coating interactions under thermal-mechanical loads and offers practical solutions for infrastructure durability enhancement.
Journal Article
A Review on Sustainable Manufacturing of Ceramic-Based Thin Films by Chemical Vapor Deposition (CVD): Reactions Kinetics and the Deposition Mechanisms
Chemical vapor deposition (CVD) is a process that a solid is formed on a substrate by the chemical reaction in the vapor phase. Employing this technology, a wide range of materials, including ceramic nanocomposite coatings, dielectrics, and single crystalline silicon materials, can be coated on a variety of substrates. Among the factors influencing the design of a CVD system are the dimensions or geometry of the substrate, substrate temperature, chemical composition of the substrate, type of the deposition process, the temperature within the chamber, purity of the target material, and the economics of the production. Three major phenomena of surface reaction (kinetic), diffusion or mass transfer reaction, and desorption reaction are involved during the CVD process. Thermodynamically, CVD technology requires high temperatures and low pressures in most systems. Under such conditions, the Gibbs free energy of the chemical system quickly reaches its lowest value, resulting in the production of solids. The kinetic control of the CVD technology should always be used at low temperatures, and the diffusion control should be done at high temperatures. The coating in the CVD technology is deposited in the temperature range of 900–1400 °C. Overall, it is shown here that by controlling the temperature of the chamber and the purity of the precursors, together with the control of the flow rate of the precursors into the chamber, it is possible to partially control the deposition rate and the microstructure of the ceramic coatings during the CVD process.
Journal Article
Glass-Ceramic Coating on Silver Electrode Surface via 3D Printing
Silver electrodes are commonly used as a conductive layer for electromagnetic devices. It has the advantages of good conductivity, easy processing, and good bonding with a ceramic matrix. However, the low melting point (961 °C) results in a decrease in electrical conductivity and migration of silver ions under an electric field when it works at high temperatures. Using a dense coating layer on the silver surface is a feasible way to effectively prevent the performance fluctuation or failure of the electrodes without sacrificing its wave-transmitting performance. Calcium-magnesium-silicon glass-ceramic (CaMgSi2O6) is a diopside material that has been widely used in electronic packaging materials. However, CaMgSi2O6 glass-ceramics (CMS) are facing tough challenges, such as high sintering temperature and insufficient density after sintering, which significantly confine its applications. In this study, CaO, MgO, B2O3, and SiO2 were used as raw materials to manufacture a uniform glass coating on the silver and Al2O3 ceramics surface via 3D printing technology followed by high-temperature sintering. The dielectric and thermal properties of the glass/ceramic layer prepared with various CaO-MgO-B2O3-SiO2 components were studied, and the protective effect of the glass-ceramic coating on the silver substrate at high temperatures were evaluated. It was found that the viscosity of the paste and the surface density of the coating increase with the increase of solid contents. The 3D-printed coating shows well-bonded interfaces between the Ag layer, the CMS coating, and the Al2O3 substrate. The diffusion depth was 2.5 μm, and no obvious pores and cracks can be detected. According to the high density and well-bonded glass coating, the silver was well protected from the corrosion environment. Increasing the sintering temperature and extending the sintering time is beneficial to form the crystallinity and the densification effect. This study provides an effective method to manufacture a corrosive-resistant coating on an electrically conductive substrate with outstanding dielectric performances.
Journal Article
A Brief Review of Current Trends in the Additive Manufacturing of Orthopedic Implants with Thermal Plasma-Sprayed Coatings to Improve the Implant Surface Biocompatibility
The demand for orthopedic implants is increasing, driven by a rising number of young patients seeking an active lifestyle post-surgery. This has led to changes in manufacturing requirements. Joint arthroplasty operations are on the rise globally, and recovery times are being reduced by customized endoprostheses that promote better integration. Implants are primarily made from metals and ceramics such as titanium, hydroxyapatite, zirconium, and tantalum. Manufacturing processes, including additive manufacturing and thermal plasma spraying, continue to evolve. These advancements enable the production of tailored porous implants with uniform surface coatings. Coatings made of biocompatible materials are crucial to prevent degradation and enhance biocompatibility, and their composition, porosity, and roughness are actively explored through biocompatibility testing. This review article focuses on the additive manufacturing of orthopedic implants and thermal plasma spraying of biocompatible coatings, discussing their challenges and benefits based on the authors’ experience with selective laser melting and microplasma spraying of metal-ceramic coatings.
Journal Article
Crack Evolution and Oxidation Failure Mechanism of a SiC-Ceramic Coating Reactively Sintered on Carbon/Carbon Composites
A SiC ceramic coating was prepared on carbon/carbon composites by pack cementation. The phase composition and microstructure of the coated specimens were characterized using X-ray diffraction instrument and scanning electron microscope. The results showed that the mass-loss percentage of the coated specimen was 9.5% after being oxidized for 20 h. The oxidation failure of the SiC ceramic coating at 1773 K was analysed by non-destructive X-ray computed tomography. The effective self-healing of cracks with widths below 12.7 μm introduced during the coating preparation process and generated while the specimens cooled down from the high oxidation temperature prevented the oxidation of carbon/carbon composites. X-ray computed tomography was used to obtain three-dimensional images revealing internal damage caused by spallation and open holes on the coating. Stress induced by heating and cooling caused the formation, growth and coalescence of cracks, which in turn led to exfoliation of the coating and subsequent failure of oxidation protection.
Journal Article
Thermal Shock Failure Analysis of LaMgAl11O19 Thick Ceramic Coatings Plasma Sprayed with Different Critical Plasma Spraying Parameters
The effect of the critical plasma spraying parameters (CPSPs) on thermal shock resistance of plasma-sprayed LaMgAl
11
O
19
coatings with thickness of 800 μm was investigated. With the CPSPs value decreased from 1.20 to 0.86, thermal cycling lifetime of the LMA coatings increased from 2571 ± 245 to 3394 ± 78 cycles during testing at 900 °C, while it increased from 300 ± 79 to 702 ± 78 cycles during testing at 1100 °C. Based on the simulation results, the normal tensile stress S
11
concentrated along the bond coat/top coat interface was decreased from 788.20 to 533.94 MPa with the decreasing CPSPs during the first cycle, while the normal tensile stress S
22
concentrated at the end of the interface reduced from 310.32 to 74.51 MPa after 10 cycles. As a result, the improvement of thermal shock resistance of coating would be attributed to the combined effects of the decrease in tensile stress S
11
and S
22
, while the stress accumulation and volume shrinkage induced by the recrystallization of amorphous phase were the main factors of coating failure.
Journal Article
Behavior of YSZ (High Y2O3 Content) Layer on Inconel to Electro-Chemical Corrosion
The high yttria content of a stabilized zirconia (YSZ) (38 wt% Y2O3) coating was deposited by atmospheric plasma spraying (APS) from Metco 207 powders on an Inconel 718 (Ni-based superalloy) substrate. As a metal coating connection, a layer of cermet powder (Ni-20% Al—410NS) was used before the ceramic layer deposition. The electro-chemical corrosion resistance of these materials was tested using Inconel cylinders with a diameter of 10 mm and a thickness of 1 mm, with and without the ceramic layer. Linear and cyclic measurements were obtained in H2SO4 electrolyte media at pH = 2. Electro-impedance spectroscopy (EIS) experiments were performed on the sample covered with the ceramic layer to evaluate the interface behavior. Scanning electron microscopy (SEM), along with equipment to determine chemical composition, and an energy dispersive spectrometry (EDS) detector were used to characterize the material surface before and after corrosion tests. It was observed that the corrosion resistance of Inconel was influenced by the bonding layer and the ceramic coating.
Journal Article
Twin Toughening‐Driven Martensitic Transformation Strategy Synergistic Improvement for Plasticity‐Thermal Shock Resistance of (Hf─Zr─Ti)C Ceramic Coating in Severe Thermal Environments
The inherent brittleness and insufficient thermal shock resistance of ultra‐high temperature ceramic (UHTC) in severe thermal environments (above 2000 °C) remain significant challenges. This characteristic notably shortens their operational lifespan as thermal protective coatings on structural composites in reusable aerospace applications. To address these challenges, a “ceramic self‐toughening strategy” is introduced, aimed at enhancing the plasticity and thermal shock resistance of (Hf─Zr─Ti)C coatings through twin toughening‐driven martensitic transformations in the oxide scale. In this work, the oxidation of (Hf1/2Zr1/4Ti1/4)C and (Hf1/4Zr1/2Ti1/4)C coatings produced Ti‐doped (Hf2/3Zr1/3)O2 and Ti‐doped (Hf1/3Zr2/3)O2, with martensitic transformations initiated by “slip band‐twin transfer” and “stacking fault‐twin transfer”, respectively. The mechanism facilitated the formation of stable, dense, and high‐toughness oxide scales after repeat ablation, and then endowed the prepared coatings with superior repeat ablation resistance than current thermal protective coatings. The findings elucidated the role of martensitic transformation mechanisms of Ti‐doped (Hf, Zr)O2 during repeat ablation, and provided general design guidelines for synergistically controlling the component, microstructure, toughness, and thermal shock resistance of UHTC blocks and UHTC‐modified composites in severe thermal environments. A “ceramic self‐toughening strategy” is introduced for enhancing the plasticity and thermal shock resistance of (Hf─Zr─Ti)C coatings through twin toughening‐driven martensitic transformations in oxide scales. It facilitated the formation of stable, dense, and high‐toughness oxide scales after repeat ablation, and endowed prepared coatings with superior repeat ablation resistance than current thermal protective coatings in severe thermal environments above 2000 °C.
Journal Article