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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
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
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
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
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
Effects of metal–ceramic anticorrosion coating on the performance of ballastless tracks at high temperature
A highly reflective metal–ceramic anticorrosion coating is proposed to address temperature-induced track arching and concomitant damage of the China Railway Track System II ballastless tracks. The term ceramic refers to the inorganic phosphate coating binder and the metal pertains to the aluminite powder filler. Its thermal properties were studied through finite element modeling and heat radiation testing of uncoated and coated concrete samples and 1:1 ballastless track slab models. The metal–ceramic anticorrosion coating microstructure and constituent characterization were considered in its cooling efficacy analysis. The insulation temperature of the concrete test pieces increased as the thickness of the primer layer increased. At a primer layer thickness of 100 μm, 200 μm, and 300 μm, the corresponding insulation temperature was 8 °C, 18 °C, and 25 °C, respectively. Moreover, the temperature gradient, longitudinal stress, and vertical displacement of a track slab coated with a 300-μm metal–ceramic anticorrosion coating layer decreased by 29%, 57%, and 51.9%, respectively, which agreed well with the simulation results. The reduction in temperature transfer to the substrate, realized by the metal–ceramic anticorrosion coating, holds great promise for application in the construction industry.
Journal Article
The influence of curing agents on thermal property and corrosion resistance of chemically bonded phosphate ceramic coatings
The curing agents play an important role on the properties of the chemically bonded phosphate ceramic coatings (CBPCs). To investigate the influence of curing agents on the thermal property and corrosion resistance of CBPCs, the coatings with different curing agents were prepared on the mild steel (Q235). The analysis of thermal property and phase characterization shows that the high peak temperature of curing decreases with the introduction of curing agents, and the weight ratio of AlPO
4
to α-Al
2
O
3
(RAA) of the coatings is also influenced by curing agents resulted by the high heat release from MgO, CaO, and ZnO-related reactions. In addition, the results of scanning electron microscopy (SEM) and electrochemical experiments reveal that the bonding strength among the ceramic particles and the defects content of the coatings, which affects the inhibition properties of CBPCs have a relationship with the value of RAA. Typically, the impedance value of CBPC with the best curing agent (MgO) are around 40,000 ohm cm
2
, which is 4624 times larger than that of the bare mild steel (8.65 ohm cm
2
).
Highlights
The effect of curing agents on thermal property and corrosion inhibition of CBPCs was studied.
The high curing temperature decreases with the introduction of curing agents.
The CBPCs with MgO agent possess the lowest curing temperature.
The AlPO4 to α-Al
2
O
3
weight ratio affects bonding strength, defects, and corrosion resistance of CBPCs.
Journal Article
Multifunctional Boehmite Grafting on Al2O3‐Coated Polypropylene Separators for Fire‐Retardant and Fast‐Rechargeable Lithium‐Ion Batteries
To improve the fire safety in lithium‐ion batteries, extensive research has investigated reinforcing the thermal and mechanical properties of the separators. Applying double‐sided ceramic coatings on separators has emerged as an irreplaceable strategy because of their electrical insulation and cost‐effectiveness. Aluminum oxide (Al2O3) has been highlighted as a reasonable ceramic material that satisfies the characteristics. However, when the temperature rises above ~150°C, the Al2O3 coating layer undergoes irreversible bond cleavage. This causes the separator to shrink when thermal runaway begins, limiting its heat dissipation ability and leading to short‐circuiting in lithium‐ion batteries. In this study, we show that introducing a small amount of boehmite (AlOOH) on top of the Al2O3 coating layer imparts a highly cohesive binding network, which restrains the bond cleavage motion even at the onset temperature for thermal runaway (shrinkage ratio of 7.9% at 150°C). This strong binding network is achieved by cross‐linking the coating layer composed of Al2O3 and polyvinylidene fluoride (PVDF)with AlOOH via hydrogen bond formation. Moreover, owing to the presence of abundant polar functional groups in AlOOH, the AlOOH‐grafted Al2O3‐coated separator (AlOOH–Al2O3 SP) shows strong permeability to lithium ions, thereby alleviating ion diffusion resistance on the anode side. This ion diffusion behavior can be maintained even when the cells assembled with AlOOH–Al2O3 SP are operated under harsh charge–discharge conditions (261.1 mAh/g after 100 cycles at 1000 mA/g and 80°C). Therefore, we believe that this multifunctionality of AlOOH–Al2O3 SP can serve as a new approach to simultaneously improve the fire retardant and fast‐recharge abilities in lithium‐ion batteries.
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