WorldWideScience

Sample records for cr coatings sprayed

  1. Effect of thermal spray processes on microstructures and properties of Ni-20%Cr coatings

    Directory of Open Access Journals (Sweden)

    Pittaya Kuntasudjai

    2006-05-01

    Full Text Available Ni-20%Cr coatings were produced using different thermal spray techniques, which were spray and fuse, flame spray and arc spray. The Ni-20%Cr powder was sprayed onto a mild steel substrate using the spray and fuse and the flame spray systems, while the Ni-20%Cr wire was sprayed using the arc spray system. SEM microstructures of the coatings suggested the spraying conditions used were able to produce dense microstructures. However, the microstructure of the arc sprayed coatings showed fine lamellar characteristics compared to the coatings prepared by the spray and fuse and the flame spray techniques. Chemical elements and oxide were quantified by EDS-SEM technique. Differences in microstructure and coating characteristics such as content of porosity and oxide due to different processing techniques significantly affected the coating properties such as adhesion strength, hardness and wear rate.

  2. Wear resistance of a Cr3C2-NiCr detonation spray coating

    Science.gov (United States)

    Wang, Jun; Wang, Jun; Sun, Baode; Guo, Qixin; Nishio, Mitsuhiro; Ogawa, Hiroshi

    2002-06-01

    Coatings can be applied to surfaces to improve the surface characteristics over those of the bulk properties and are widely used in tribological applications either to reduce wear and/or to modify friction during contact. One of the foremost coating methods for combating wear is thermal spraying. To prolong the life of steel slab continuous casting rolls, Cr3C2-NiCr detonation spray coating was processed on the roll surface in a steelmaking plant in China. This article studies the mechanical properties and wear resistance of this coating. The abrasive and dry frictional wear testing were performed using a pin-on-disk tester. Experimental results show that the wear resistance of the coated samples, i.e., coating reduces the risk of seizure compared to uncoated samples, is much better than those of the uncoated steel at room and elevated temperatures with any load and sliding velocity. The coating wear mechanisms under different test conditions are discussed.

  3. Blanching resistant Cu-Cr coating by vacuum plasma spray

    Energy Technology Data Exchange (ETDEWEB)

    Chiang, K.T. [Rockwell International Corp., Canoga Park, CA (United States). Rocketdyne Div.; Krotz, P.D. [Rockwell International Corp., Canoga Park, CA (United States). Rocketdyne Div.; Yuen, J.L. [Rockwell International Corp., Canoga Park, CA (United States). Rocketdyne Div.

    1995-11-01

    Copper alloy rocket engine combustion chamber linings have been found to deteriorate when exposed to cyclic reducing oxidizing (redox) environments, which are a consequence of the combustion process. The deterioration, known as blanching, can be characterized by increased roughness and burn-through sites in the wall of the combustion chamber lining and can seriously reduce the operational lifetime of the combustion chamber. A Cu-30 vol.%Cr coating produced by vacuum plasma spraying was effective in protecting the copper alloy substrate against blanching. The coating properties were characterized after cyclic oxidation exposure to 650 C in air followed by high pressure hydrogen charging. When exposed to an oxidizing environment at high temperatures, the coating formed a protective chromia scale that was substantially unreduced by high pressure hydrogen. (orig.)

  4. Properties of Cr3C2-NiCr Cermet Coating Sprayed by High Power Plasma and HVOF Processes

    OpenAIRE

    Otsubo, Fumitaka; Era, Hidenori; Kishitake, K; Uchida, T.

    2000-01-01

    The structure, hardness and shear adhesion strength have beeninvestigated in Cr3C2-NiCr cermet coatings sprayed onto a mild steelsubstrate by 200 kW high power plasma spraying (HPS) and high velocityoxy-fuel (HVOF) processes. Amorphous and supersaturated nickel phasesform in both as-sprayed coatings. The hardness of the HVOF coating ishigher than that of the HPS coating because the HVOF coating containsmore non-melted Cr3C2 carbide particles. On heat-treating at 873 K, theamorphous phase deco...

  5. Effect of High Velocity Arc Spraying Parameters on Properties of FeNiCrAl Coating

    Directory of Open Access Journals (Sweden)

    TIAN Haoliang

    2016-12-01

    Full Text Available FeNiCrAl coating is a kind of surface wear resistant material for shaft parts. Microstructure, adhesive strength, phase composition and microhardness were analyzed in order to study the influence mechanism of spraying parameters on coating properties. The relation among the spraying current, coating microstructure and cohesive strength was studied in detail. The results shown that the spraying current is very important to obtain the dense coating (porosity of 8.76% with cohesive strength of 52.3 MPa and an excellent coating is prepared by spraying current 200 A, spraying voltage 34 V and spraying distance 160 mm. The hardness of coating is 626 HV0.1 and about 1.6 times as that of the matrix. The effective mechanism is relevant to the scatter distribution of the Fe-Al intermetallic compound and Cr0.19Fe0.1Ni0.11 solution in the coating.

  6. Corrosion behavior of NiCrBSi coatings deposited by HVOF spraying

    Institute of Scientific and Technical Information of China (English)

    赵卫民; 王勇; 吴开源; 薛锦

    2003-01-01

    The corrosion resistance of NiCrBSi coating deposited on steel substrate by HVOF was examined using electrochemical tests and immersion tests so as to offer an experimental basis to expand a promising applied field of HVOF in aqueous medium, comparing with those of coatings deposited by oxyacetylene flame spraying and flame cladding. The results show that the general corrosion rate of HVOF sprayed coatings is quite bigger than that of clad coatings, but it is less sensitive to local corrosion. There is less and smaller porosity in the coatings deposited by HVOF than that in flame sprayed coatings. The effects of porosity on the corrosion current density was indistinctive, but the existence of large amount of defects in the coatings damaged the cohesion of the coatings, causing the metallic particles drop off from the coatings under the influence of corrosive medium. Improving the quality and reducing the porosity of coatings is the key to get the coatings with high corrosion resistance.

  7. Effects of Bond Coating on NiCrBSi-Mo Composite Functional Coating Properties in Plasma Spraying NiCrBSi-Mo/Ni Coating

    Directory of Open Access Journals (Sweden)

    DU Ji-yu

    2017-09-01

    Full Text Available Nickel-based bond coating and composite functional coating were sprayed on leaf blade steel material FV520B successively by using air plasma spraying system. NiCrBSi-Mo powder deposition rate, coating porosity, bonding strength and surface hardness were tested. The results indicate that, for the NiCrBSi-Mo/Ni coating, bond coating with 180-220μm thickness can improve NiCrBSi-Mo powder deposition rate while the surface coating with lower porosity, higher bonding strength and high hardness is prepared; the increase of bond coating thickness can lead to increase of functional coating porosity in the bottom and speed up the process of porosity attenuating in the vertical direction.SEM analysis found that the increase of bond coating thickness results in the droplet deposition morphology change in the bending interface with the functional coating. The defects of bond coating have genetic influence on composite functional coating. Bond tensile test results show that excessive bond coating thickness will cause fracture in the interface between bond coating and functional coating during the stretching process; in different grinding surfaces, Vickers hardness of test blocks with a certain bood coating thickness attenuates slowly in the vertical direction. NiCrBSi-Mo/Ni coating not only maintains high surface hardness, but also increases the coating thickness to repair surface damage.

  8. Corrosion and oxidation properties of NiCr coatings sprayed in presence of gas shroud system

    Energy Technology Data Exchange (ETDEWEB)

    Morks, M.F., E-mail: mhanna@swin.edu.au [Industrial Research Institute Swinburne, Swinburne University of Technology, Hawthorn, Melbourne, VIC 3122 (Australia); Berndt, C.C. [Industrial Research Institute Swinburne, Swinburne University of Technology, Hawthorn, Melbourne, VIC 3122 (Australia)

    2010-04-15

    The oxidation of a NiCr bond coat during air plasma spraying was controlled by designing a gas shroud system attached to the plasma torch nozzle. Two nozzles, termed as 'normal' and 'high-speed' nozzles examined the effect of nozzle internal design on the microstructure and phase structure of coatings. X-ray diffraction and SEM morphologies showed that the shroud system reduced the oxidation of NiCr particles during the spray process. Compared with conventional air plasma spraying, the argon gas shroud reduced the coating hardness because the volume fraction of partially melted particles increased. The high-speed nozzle reduced the oxidation and hardness of NiCr coatings due to the increase of partially melted particles in the coatings.

  9. High temperature wear performance of HVOF-sprayed Cr3C2-WC-NiCoCrMo and Cr3C2-NiCr hardmetal coatings

    Science.gov (United States)

    Zhou, Wuxi; Zhou, Kesong; Li, Yuxi; Deng, Chunming; Zeng, Keli

    2017-09-01

    A novel Cr3C2-WC-NiCoCrMo and commercial Cr3C2-NiCr thermal spray-grade powders with particle size of -45 + 15 μm were prepared by an agglomeration and sintering process. Cr3C2-WC-NiCoCrMo and Cr3C2-NiCr coatings were deposited by high velocity oxygen fuel (HVOF) spraying. The fundamental properties of both coatings were evaluated and friction wear test against Al2O3 counterbodies of both coatings at high temperatures (450 °C, 550 °C, 650 °C) were carried out ball-on-disk high temperature tribometer. All specimens were characterized by optical microscopy, X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), scanning electron microscopy with energy dispersive spectroscopy (SEM/EDS) and 3D non-contact surface mapping profiler. The results have shown that the Cr3C2-WC-NiCoCrMo coating exhibited lower porosity, higher micro-hardness compared to the Cr3C2-NiCr coating. The Cr3C2-WC-NiCoCrMo coating also exhibited better wear resistance and higher friction coefficient compared to the Cr3C2-NiCr coating when sliding against the Al2O3 counterpart. Wear rates of both coatings increased with raising temperature. Both coatings experienced abrasive wear; hard phase particles (WC and Cr3C2) with different sizes, distributed in the matrix phase, will effectively improve the resistance against wear at high temperatures.

  10. Thermal Stress and Residual Stress Control of Thermally Sprayed 80Ni20Cr Coating

    OpenAIRE

    Ishida, Tsuyoshi; Setoguchi, Katsuya; Hiraki, Kunihiro

    1999-01-01

    In order to find an effective method to control the residual coating stress after thermal spraying, an analysis and experiment were carried out on a cylindrical member of 80Ni20Cr/SUS304. Temperature measurements during the processes of thermal spraying, heating and cold thermal shock were carried out. Using these measured results, thermal stress analyses were perfomed by the finite element method(FEM) and a proposed simplified method for estimating the coating stress. Thermal stress of the c...

  11. Microstructure and mechanical properties of thermal sprayed nanostructured Cr3C2-Ni20Cr coatings

    OpenAIRE

    Cecilio Alvares da Cunha; Nelson Batista de Lima; Jose Roberto Martinelli; Ana Helena de Almeida Bressiani; Armando Guilherme Fernando Padial; Lalgudi Venkataraman Ramanathan

    2008-01-01

    Cr3C2-Ni20Cr coatings have been used for corrosion and wear resistant applications. However, one of the shortcomings of these coatings is its low hardness, and consequent low wear resistance, for long term high temperature applications. Nanostructured coatings of many materials have exhibited higher hardness and strength compared with conventional coatings of the same material. Consequently, nanostructured coatings of other materials, including Cr3C2-Ni20Cr have been attempted to enhance over...

  12. Mechanical properties and microstructure of vaccum plasma sprayed Cr3C2 - 25(Ni20Cr) coatings

    OpenAIRE

    MRDAK MIHAILO R.

    2015-01-01

    This paper analyzes vacuum plasma spray VPS - Cr3C2 - 25(Ni20Cr) coatings. Commercial powder marked Sulzer Metco Woka 7205 is used. The powder is deposited with a plasma gun F4 at a distance of 340 mm from the substrate. The main objective of the study was to eliminate, at the reduced pressure of inert gas Ar, the degradation of primary Cr3C2 carbide into Cr23C6 carbide which significantly reduces the microhardness and mechanical properties of the coating. The coating is deposited with a thic...

  13. Wear and corrosion resistance of laser remelted and plasma sprayed Ni and Cr coatings on copper

    Institute of Scientific and Technical Information of China (English)

    梁工英; 黄俊达; 安耿

    2004-01-01

    Nickel and chromium coatings were produced on the copper sheet using plasma spraying and laser remelting. The sliding wear test was achieved on a block-on-ring tester and the corrosion test was carried out in an acidic atmosphere. The corrosive behaviors of both coatings and original copper samples were investigated by using an impedance comparison method. The experimental results show that the nickel and chromium coatings display better wear resistance and corrosion resistance relative to the original pure copper sample. The wear resistance of the coatings is 8 - 12 times as large as original samples, and the wear resistance of laser remelted samples is better than that of plasma sprayed ones. The corrosion resistance of laser remelted nickel and chromium samples is better than that of plasma sprayed samples respectively. The corrosion rate of chromium coatings is less than that of nickel coatings, and the laser remelted Cr coating exhibits the least corrosion rate.

  14. Creep behavior of plasma sprayed NiCr and NiCrAl coating-based systems

    Institute of Scientific and Technical Information of China (English)

    Xiancheng ZHANG; Changjun LIU; Fuzhen XUAN; Zhengdong WANG; Shan-Tung TU

    2011-01-01

    The creep behavior of the plasma sprayed NiCr and NiCrAl coating/Nickel alloy 690substrate systems at 1033 K was investigated. Results showed that there was almost no difference in the creep lives between the NiCr and NiCrAl coated specimens at a given stress level, since the contents of Cr used in the NiCr and NiCrAl powders are almost same. The relationship between the minimum creep rate and the applied stress followed the well-known Norton's power law, εmin=Aσn, with the values of A=2.66× 10-16 Mpa-n.h-1 and n=6.48. The relation between the applied stress and time to rupture of the coated specimens can be estimated by using Larson-Miller equation. The θ projection method can be used to accurately characterize the creep behavior of the coated specimens.

  15. Microstructure and Properties of FeCrB Alloy Coatings Prepared by Wire-Arc Spraying

    Science.gov (United States)

    Yao, H. H.; Zhou, Z.; Wang, Y. M.; He, D. Y.; Bobzin, K.; Zhao, L.; Öte, M.; Königstein, T.

    2017-02-01

    To improve the heat transfer ability and wear resistance of drying cylinders in paper production machines, a series of Fe87- x Cr13B x ( x = 1 wt.%, 1.5 wt.%, 2 wt.%, 2.5 wt.%, 3 wt.%, and 4 wt.%) cored wires have been produced and used to prepare coatings by wire-arc spraying, in comparison with conventional X30Cr13 solid wire. All coatings presented dense layered structure with porosity of around 4%. The boron content in the cored wires significantly affected the thermal conductivity of the coating, which is attributed to the combined effects of the crystal structure, grain size, and oxide content of the coating. In the investigated range, the coating with 2 wt.% boron content exhibited the highest thermal conductivity, reaching 8.83 W/m-K, greater than that of X30Cr13 coating (5.45 W/m-K). Furthermore, the microhardness and relative wear resistance of the FeCrB coatings obtained from cored wires with boron addition were greatly increased compared with commercial X30Cr13 coating. Therefore, wire-arc-sprayed FeCrB coating has promise as an effective and economic approach to improve the heat transfer behavior and wear resistance of drying cylinders in the paper industry.

  16. Microstructure and Properties of FeCrB Alloy Coatings Prepared by Wire-Arc Spraying

    Science.gov (United States)

    Yao, H. H.; Zhou, Z.; Wang, Y. M.; He, D. Y.; Bobzin, K.; Zhao, L.; Öte, M.; Königstein, T.

    2016-12-01

    To improve the heat transfer ability and wear resistance of drying cylinders in paper production machines, a series of Fe87-x Cr13B x (x = 1 wt.%, 1.5 wt.%, 2 wt.%, 2.5 wt.%, 3 wt.%, and 4 wt.%) cored wires have been produced and used to prepare coatings by wire-arc spraying, in comparison with conventional X30Cr13 solid wire. All coatings presented dense layered structure with porosity of around 4%. The boron content in the cored wires significantly affected the thermal conductivity of the coating, which is attributed to the combined effects of the crystal structure, grain size, and oxide content of the coating. In the investigated range, the coating with 2 wt.% boron content exhibited the highest thermal conductivity, reaching 8.83 W/m-K, greater than that of X30Cr13 coating (5.45 W/m-K). Furthermore, the microhardness and relative wear resistance of the FeCrB coatings obtained from cored wires with boron addition were greatly increased compared with commercial X30Cr13 coating. Therefore, wire-arc-sprayed FeCrB coating has promise as an effective and economic approach to improve the heat transfer behavior and wear resistance of drying cylinders in the paper industry.

  17. Influence of powder and spray parameters on erosion and corrosion properties of HVOF sprayed WC-Co-Cr coatings

    Energy Technology Data Exchange (ETDEWEB)

    Berget, John

    1998-07-01

    Thermal spraying is a generic term including various processes used to deposit coatings on surfaces. The coating material is in the form of powder or a wire and is melted or softened by means of a heat source. A gas stream accelerates the material towards a prepared surface and deposits it there to form the coating. Examples of components being maintained by application of thermal spray coatings are gate valves and ball valves for the offshore industry and turbine blades in power generations installations. Recent investigation has shown that the commonly used coating material WC-Co is not corrosion resistant. But it can be improved by the addition of Cr. The main objective of this thesis is to study the influence of spray process control variables and powder characteristics on the erosion and erosion-corrosion properties of the coatings. Spray process variables investigated include energy input, powder feed rate and spray distance. Powder characteristics studied are average size of the WC particles, relative proportions of Co and Cr in the metal phase and powder grain size distribution.

  18. Tribological and Oxidative Behavior of Thermally Sprayed NiCrBSi Coatings

    Science.gov (United States)

    Garrido, M. A.; Rico, A.; Gómez, M. T.; Cadenas, M.; Fernández-Rico, J. E.; Rodríguez, J.

    2017-01-01

    The behavior of NiCrBSi coatings deposited by three different spraying techniques was studied: flame spray with a subsequent flame treatment (FS + Flame), flame spray with post-laser treatment (FS + Laser) and laser cladding (LC). The coating responses under wear and oxidation conditions were analyzed. Although the microstructure of the coatings deposited by the three different techniques showed similar phases and precipitates, some changes in the size and distribution of these constituents were observed. The pin on disk configuration was used to determine the friction coefficients and wear rates. LC coatings showed the highest wear resistance, with plastic deformation being the main wear mechanism identified for all of the coatings analyzed. Tests under aggressive environments were also performed to determine the oxidation kinetics.

  19. Tribological and Oxidative Behavior of Thermally Sprayed NiCrBSi Coatings

    Science.gov (United States)

    Garrido, M. A.; Rico, A.; Gómez, M. T.; Cadenas, M.; Fernández-Rico, J. E.; Rodríguez, J.

    2017-02-01

    The behavior of NiCrBSi coatings deposited by three different spraying techniques was studied: flame spray with a subsequent flame treatment (FS + Flame), flame spray with post-laser treatment (FS + Laser) and laser cladding (LC). The coating responses under wear and oxidation conditions were analyzed. Although the microstructure of the coatings deposited by the three different techniques showed similar phases and precipitates, some changes in the size and distribution of these constituents were observed. The pin on disk configuration was used to determine the friction coefficients and wear rates. LC coatings showed the highest wear resistance, with plastic deformation being the main wear mechanism identified for all of the coatings analyzed. Tests under aggressive environments were also performed to determine the oxidation kinetics.

  20. Microstructure and properties of thermal-sprayed NiCrWRE coatings

    Institute of Scientific and Technical Information of China (English)

    ZHANG Zhenyu; WANG Zhiping; LIANG Bunv

    2008-01-01

    The powders of NiCrW and NiCrWRE alloys were flame sprayed on a medium-carbon steel substrate by thermal spray welding. The microstructure and tribological behavior of coatings were studied experimentally by means of scanning electron microscopy (SEM), field emission gun scanning electron microscope (FEGSEM), and wear tests. The addition of CeO2 modifies the coating morphology from a needle-like structure to a roughly cubic morphology; the refining and purifying effect of rare earth elements makes the microstructure more compact and finer. Analysis of the worn surfaces reveals that the coatings with CeO2 addition show improved abrasive wear resistance over those without CeO2. By adding CeO2, the hardness of the coatings is significantly increased, and the wear resistance of the coatings is enhanced.

  1. Cyclic Oxidation Behavior of CuCrAl Cold-Sprayed Coatings for Reusable Launch Vehicles

    Science.gov (United States)

    Raj, Sai; Karthikeyan, J.

    2009-01-01

    The next generation of reusable launch vehicles is likely to use GRCop-84 [Cu-8(at.%)Cr-4%Nb] copper alloy combustion liners. The application of protective coatings on GRCop-84 liners can minimize or eliminate many of the environmental problems experienced by uncoated liners and significantly extend their operational lives and lower operational cost. A newly developed Cu- 23 (wt.%) Cr-5% Al (CuCrAl) coating, shown to resist hydrogen attack and oxidation in an as-cast form, is currently being considered as a protective coating for GRCop-84. The coating was deposited on GRCop-84 substrates by the cold spray deposition technique, where the CuCrAl was procured as gas-atomized powders. Cyclic oxidation tests were conducted between 773 and 1,073 K to characterize the coated substrates.

  2. Biofouling of Cr-Nickel Spray Coated Films on Steel Surfaces

    Science.gov (United States)

    Yoshida, Kento; Kanematsu, Hideyuki; Kuroda, Daisuke; Ikigai, Hajime; Kogo, Takeshi; Yokoyama, Seiji

    2012-03-01

    , the former showed higher antifouling properties generally. Aluminium-zinc alloy spray coated films had higher antifouling property. And the anti-property decreased in this order: Al-Zn alloy spray coating > Zinc spray coating > Aluminium spray coating > Stacked chromium/nickel spray coating. Aluminium and zinc spray coating has been evaluated high conventionally for anti-biofouling in marine environment. However, the Cr/Ni spray coating showed pretty high anti-fouling property.

  3. Influences of gas flow rates on melting of particles of HVOF sprayed CoCrW coating and coating properties

    Institute of Scientific and Technical Information of China (English)

    YANG Zhongyuan

    2004-01-01

    This paper discussed influences of flow rates of O2, C3H8, and compressed air on the melting degree of particles during HVOF (high velocity oxy-fuel) sprayed CoCrW coating. The O2 flow rate has the maximal effect on the melting of particles, the C3H8 flow rate has the second, and the compressed air flow rate has the minimal effect. The bond strength of the HVOF sprayed CoCrW coating is over 54 MPa. The porosity ratio of the HVOF sprayed CoCrW coating after optimization of gas flow rates is less than 2%. The average microhardness of the coating is up to HV0.1 545. The oxidation amount per unit area of the HVOF sprayed CoCrW coating increases with the holding time increasing at 800°C. In the same way,the oxidation amount of the coating increases as the temperature increases. Particularly, the oxidation of the coating drastically increases over 850°C.

  4. Abrasive Wear Study of NiCrFeSiB Flame Sprayed Coating

    Science.gov (United States)

    Sharma, Satpal

    2013-10-01

    In the present study, abrasive wear behavior of NiCrFeSiB alloy coating on carbon steel was investigated. The NiCrFeSiB coating powder was deposited by flame spraying process. The microstructure, porosity and hardness of the coatings were evaluated. Elemental mapping was carried out in order to study the distribution of various elements in the coating. The abrasive wear behavior of these coatings was investigated under three normal loads (5, 10 and 15 N) and two abrasive grit sizes (120 and 320 grit). The abrasive wear rate was found to increase with the increase of load and abrasive size. The abrasive wear resistance of coating was found to be 2-3 times as compared to the substrate. Analysis of the scanning electron microscope images revealed cutting and plowing as the material removal mechanisms in these coatings under abrasive wear conditions used in this investigation.

  5. Corrosive wear behaviours of HVOF-sprayed NiCr coatings on stainless steel substrates

    Energy Technology Data Exchange (ETDEWEB)

    Ak, N.F.; Celik, E.; Cetinel, H.; Tekmen, C. [Dokuz Eyluel Univ., Dept. of Metallurgy and Materials Engineering, Bornova, Izmir (Turkey); Soykan, H.S. [Kocaeli Univ., Dept. of Metallurgy and Materials Engineering, Izmit-Kocaeli (Turkey)

    2004-07-01

    The High Velocity Oxy-Fuel (HVOF) thermal spraying process can be used to produce dense hard coatings onto metallic surfaces with a good bond between the coating and substrate. These coatings have been applied in many different industries to provide wear, erosion and corrosion protection. In this study, the NiCr coatings were deposited on the stainless steel substrates by HVOF technique. Microstructural characterization of the coatings was examined by using optical microscope. Corrosive wear behaviour of these coatings was evaluated through a pin-on-plate configuration, the wear tests were carried out at ambient temperature in 1% H{sub 2}SO{sub 4} solutions. It has been found that NiCr coating is more resistance against to wear in acid condition rather than air condition. (orig.)

  6. Fatigue properties of 48MnV steel with twin arc spraying 3Cr13 coatings

    Institute of Scientific and Technical Information of China (English)

    ZHANG Guo-qing; SU Bing; PU Geng-qiang; WANG Cheng-tao

    2005-01-01

    The fatigue behaviors of 48MnV steel, both uncoated and coated with different thicknesses of 3Cr13 deposits using twin arc spraying, were investigated. The fatigue properties of the 48MnV steel, determined under axial loading conditions, can be substantially decreased by coating 3Cr13 films, deposited by twin arc spraying. And the fatigue behavior of the thinner coatings is better than that of the thicker ones, of which the fatigue limits decrease by 9%- 14%. The decrease in fatigue life attributes to the less mechanical properties of the coatings in comparison with those of the substrate, their relative bad bonding strength and trapped oxide or Al2O3 particles retain in the matrix after blasting responsible for the initiation of fatigue cracks.

  7. Microstructural characteristics and mechanical properties of HVOF sprayed NiCrAl coating on superalloys

    Energy Technology Data Exchange (ETDEWEB)

    Mahesh, R.A. [Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, Roorkee 247667 (India); Jayaganthan, R. [Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, Roorkee 247667 (India)], E-mail: rjayafmt@iitr.ernet.in; Prakash, S. [Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, Roorkee 247667 (India)

    2009-01-22

    High velocity oxy-fuel (HVOF) process sprayed NiCrAl coatings on superalloys were characterized by various techniques such as optical microscopy, X-ray diffraction (XRD) and scanning electron microscopy/energy dispersive spectroscopic analysis (SEM/EDS) to render an insight into their microstrucural features and assess its suitability for high temperature corrosion resistance applications. The as sprayed coatings were found to be dense with splat like layered morphology. The XRD analysis of the coating showed the presence of Ni (fcc) as a prominent phase with Cr and Al as minor phases. The porosity of the coatings was calculated from its optical micrographs and found to be less than 1.7%. The measured hardness and average bond strength of the coatings were found to be in the range of 278-351 Hv and 59 MPa, respectively. The observed microstructral characteristics, higher bond strength, and hardness of HVOF sprayed NiCrAl coating show that it may act as an effective barrier to provide high temperature protection to the superalloys.

  8. Thermal failure of nanostructured thermal barrier coatings with cold sprayed nanostructured NiCrAlY bond coat

    Energy Technology Data Exchange (ETDEWEB)

    Zhang, Q.; Li, Y.; Zhang, S.L.; Wang, X.R.; Yang, G.J.; Li, C.X.; Li, C.J. [Xi' an Jiaotong Univ., Xi' an (China)

    2008-07-01

    Nanostructured YSZ is expected to exhibit a high strain tolerability due to its low Young's modulus and consequently high durability. In this study, a porous YSZ as the thermal barrier coating was deposited by plasma spraying using an agglomerated nanostructured YSZ powder on a Ni-based superalloy Inconel 738 substrate with a cold-sprayed nanostructured NiCrAlY as the bond coat. The heat treatment in Ar atmosphere was applied to the cold-sprayed bond coat before deposition of YSZ. The isothermal oxidation and thermal cycling tests were applied to examine failure modes of plasma-sprayed nanostructured YSZ. The results showed that YSZ coating was deposited by partially melted YSZ particles. The nonmelted fraction of spray particles retains the porous nanostructure of the starting powder into the deposit. YSZ coating exhibits a bimodal microstructure consisting of nanosized particles retained from the powder and micro-columnar grains formed through the solidification of the melted fraction in spray particles. The oxidation of the bond coat occurs during the heat treatment in Ar atmosphere. The uniform oxide at the interface between the bond coat and YSZ can be formed during isothermal test. The cracks were observed at the interface between TGO/BC or TGO/YSZ after thermal cyclic test. However, the failure of TBCs mainly occurred through spalling of YSZ within YSZ coating. The failure characteristics of plasma-sprayed nanostructured YSZ are discussed based on the coating microstructure and formation of TGO on the bond coat surface. (orig.)

  9. Microstructural Characteristics and Oxidation Behavior of Low-Pressure Cold-Sprayed CoNiCrAlY Coatings

    Science.gov (United States)

    Zhang, Lin-wei; Lu, Lei; Wang, Lu; Ning, Xian-jin; Wang, Quan-sheng; Wang, Ri-xin

    2017-09-01

    CoNiCrAlY coatings were deposited by low-pressure cold spraying and subsequently heat-treated at 1050 °C for 4 h in a vacuum environment. The microstructural characteristics and oxidation behavior of CoNiCrAlY coatings were investigated. The as-sprayed coating exhibited low porosity and oxygen content. The high plastic deformation of the sprayed particles led to significant refinement of γ-matrix and dissolution of β-(Ni,Co)Al phase in the as-sprayed coating. After heat treatment, the single phase (γ) in the as-sprayed coating was converted into a γ/β microstructure, and a continuous single α-Al2O3 scale was formed on the coating surface. Vacuum heat treatment can postpone the formation of spinel oxides within 100 h. After being oxidized at 1050 °C for 400 h, the heat-treated coating exhibited better oxidation resistance than the as-sprayed coating. The reduced growth rate of the oxide scale and the suppression of the formation of spinel oxides can be attributed to the vacuum heat treatment, as well as the intrinsic microstructure of the cold-sprayed coating. Finally, the effects of the microstructural changes induced during the cold spraying process on the growth of the thermally grown oxide and the oxidation mechanisms of the CoNiCrAlY coatings were discussed.

  10. Erosion-Corrosion Behaviors of High Velocity Arc Sprayed Fe-Al/Cr3C2 Coating

    Institute of Scientific and Technical Information of China (English)

    XU Weipu; XU Binshi; ZHANG Wei; WU Yixiong

    2006-01-01

    Iron aluminide intermetallic coatings were prepared from Fe-Al/Cr3C2 cored wires using High Velocity Arc Spraying (HVAS) technology. Erosion and corrosion properties of HVAS sprayed Fe-Al/Cr3C2 coatings were investigated. Results show that the erosion at impingement angle of 30° is more than that of 90°. The erosion resistance of coatings was enhanced with the increase of temperature. Coatings had a better erosion resistance than substrates. The erosion changed from ductile behaviors to brittle behaviors above 450 ℃. At high temperature, the erosion resistances were superior to those at low temperature and room temperature. Coatings had much higher corrosion properties than substrates. The temperature had a little effect on the corrosion resistance of coatings; The corrosion losing of coatings increased slowly with the increase of corrosion time. The HVAS-sprayed Fe-Al/Cr3C2 coatings exhibited a high bond strength and hardness.

  11. A Study of Cr3C2-Based HVOF- and HVAF-Sprayed Coatings: Microstructure and Carbide Retention

    Science.gov (United States)

    Matikainen, V.; Bolelli, G.; Koivuluoto, H.; Honkanen, M.; Vippola, M.; Lusvarghi, L.; Vuoristo, P.

    2017-08-01

    The research on high-velocity air-fuel (HVAF)-sprayed Cr3C2-based materials has mostly focused on conventional Cr3C2-25NiCr composition. In this paper, two alternative compositions (Cr3C2-50NiCrMoNb and Cr3C2-37WC-18NiCoCrFe) were sprayed with high-velocity oxy-fuel (HVOF) and HVAF spray processes to evaluate the material behavior during spraying and to provide characterization of the microstructures and mechanical properties of the coatings. For comparison, coatings from the Cr3C2-25NiCr composition were sprayed with both processes. Spray diagnostics were carried out to obtain average particle velocity and temperature for each material and process combinations. The measured average in-flight particle data were 1800 °C and 700 m/s for HVOF process, and 1450 °C and 900 m/s for HVAF process. Characterization of the coating microstructures was carried out by scanning electron microscopy and X-ray diffraction. In addition, the carbon content of the feedstock powders and sprayed coatings was measured with carbon analyzer. The results show that carbide rebounding or selective deposition of particles with higher metal matrix content is the dominating reason for carbide loss during HVAF spraying, while carbide dissolution is an additional source for the HVOF spraying. Higher particle velocities and controlled temperature measured for the HVAF process produced dense coatings with improved toughness and more homogenous coating structure.

  12. Influence of oxides on high velocity arc sprayed Fe-Al/Cr3C2 composite coatings

    Institute of Scientific and Technical Information of China (English)

    XU Bin-shi; ZHANG Wei; XU Wei-pu

    2005-01-01

    Fe-Al/Cr3 C2 coatings were sprayed on low steel by high velocity arc spraying(HVAS) technology. The influences of oxides on erosion, corrosion and wear behavior for high velocity arc sprayed Fe-Al/Cr3C2 coatings were studied. The results show that HVAS-sprayed Fe-Al/Cr3 C2 coatings have good erosion, heat corrosion and wear resistance. The erosion resistance improves with the increase of the temperature. On one hand, the ferrous oxides are incompact, so they peel off the surface of the coatings easily during the high temperature erosion. On the other hand, compact Al2O3 films on the surface can protect the coatings.

  13. Effect of Sealing Treatment on Corrosion Resistance of Plasma-Sprayed NiCrAl/Cr2O3-8 wt.%TiO2 Coating

    Science.gov (United States)

    Zhang, Jingjing; Wang, Zehua; Lin, Pinghua; Lu, Wenhuan; Zhou, Zehua; Jiang, Shaoqun

    2011-03-01

    Plasma-sprayed ceramic coatings inherently contain pores and micro-cracks which is deleterious when performed in aggressive environment. Various methods were applied to the as-sprayed coatings in order to improve the corrosion resistance. In the investigation of this study, plasma-sprayed NiCrAl/Cr2O3-8 wt.%TiO2 coatings were sealed by epoxy resin and silicone resin, respectively. Coatings were characterized by scanning electron microscopy/energy dispersive spectroscopy (SEM/EDS), optical microscopy (OM) and x-ray diffraction (XRD). The possible corrosion mechanism was discussed. The results of salt spray test and electrochemical measurements indicated that after the sealing treatment, the porosity of coatings decreased obviously and a compact layer was formed to protect the coating from corrosion. The silicone resin proved to be more effective than epoxy resin in enhancing the corrosion resistance of the coatings used in this research.

  14. Protection of carbon steel against hot corrosion using thermal spray Si- and Cr-base coatings

    Science.gov (United States)

    Porcayo-Calderon, J.; Gonzalez-Rodriguez, J. G.; Martinez, L.

    1998-02-01

    A Fe75Si thermal spray coating was applied on the surface of a plain carbon steel baffle plate. Beneath this coating, a Ni20Cr coating was applied to give better adherence to the silicon coating. The baffle was installed in the high-temperature, fireside, corrosion zone of a steam generator. At the same time, an uncoated 304 stainless steel baffle was installed nearby for comparison. For 13 months the boiler burned heavy fuel oil with high contents of vanadium. The samples were studied employing scanning electron microscopy, x-ray microanalysis, and x-ray diffraction techniques. After that, it was possible to inspect the structural state of the components, and it was found that the stainless steel baffle plates were destroyed almost completely by corrosion, whereas the carbon steel coated baffle plate did not suffer a significant attack, showing that the performance of the thermal spray coating was outstanding and that the coating was not attacked by vanadium salts of the molten slag.

  15. Comparing study of high temperature erosion of HVOF sprayed Cr{sub 3}C{sub 2}-NiCr coating and mild steel for boiler tube

    Energy Technology Data Exchange (ETDEWEB)

    Yang, G.; Zhang, S.; Wang, Y.; Li, C.; Li, C. [Xi' an Jiaotong Univ., Xi' an (China)

    2008-07-01

    The significant erosion of the boiler tube at high temperature becomes an important problem for the safe operation of circulating fluidized bed boiler. This paper investigated the erosion behavior of the HVOF sprayed Cr{sub 3}C{sub 2}-NiCr coating at high temperature comparing with the typical mild steel for boiler tube. Results showed that the erosion rate of the mild steel increased with the increase of temperature. The erosion rate of the mild steel at 800 C was 4 times that at 300 C at an erosion angle of 30 . However, the erosion rate of the HVOF sprayed Cr{sub 3}C{sub 2}-NiCr coating was not influenced by the temperature in the range of 300 to 800 C. It is found that the erosion resistance of HVOF sprayed Cr{sub 3}C{sub 2}-NiCr coating was more than 3 time higher than that of the mild steel at 700 to 800 C. In addition to the ploughing on the surface of the worn coating, the cracking along splats interfaces in the coating was clearly observed on the cross-sectional microstructure of the coating. The results indicate that the erosion performance of the HVOF sprayed Cr{sub 3}C{sub 2}-NiCr coating is controlled by the cohesion between splats in the coating and can be further enhanced by improving splat cohesion. (orig.)

  16. Mechanical and Tribological Properties of HVOF-Sprayed (Cr3C2-NiCr+Ni) Composite Coating on Ductile Cast Iron

    Science.gov (United States)

    Ksiazek, Marzanna; Boron, Lukasz; Radecka, Marta; Richert, Maria; Tchorz, Adam

    2016-08-01

    The aim of the investigations was to compare the microstructure, mechanical, and wear properties of Cr3C2-NiCr+Ni and Cr3C2-NiCr coatings deposited by HVOF technique (the high-velocity oxygen fuel spray process) on ductile cast iron. The effect of nickel particles added to the chromium carbide coating on mechanical and wear behavior in the system of Cr 3 C 2 -NiCr+Ni/ductile cast iron was analyzed in order to improve the lifetime of coated materials. The structure with particular emphasis of characteristic of the interface in the system of composite coating (Cr 3 C 2 -NiCr+Ni)/ductile cast iron was studied using the optical, scanning, and transmission electron microscopes, as well as the analysis of chemical and phase composition in microareas. Experimental results show that HVOF-sprayed Cr3C2-NiCr+Ni composite coating exhibits low porosity, high hardness, dense structure with large, partially molten Ni particles and very fine Cr3C2 and Cr7C3 particles embedded in NiCr alloy matrix, coming to the size of nanocrystalline. The results were discussed in reference to examination of bending strength considering cracking and delamination in the system of composite coating (Cr 3 C 2 -NiCr+Ni)/ductile cast iron as well as hardness and wear resistance of the coating. The composite structure of the coating provides the relatively good plasticity of the coating, which in turn has a positive effect on the adhesion of coating to the substrate and cohesion of the composite coating (Cr3C2-NiCr+Ni) in wear conditions.

  17. Vacuum plasma spray coating

    Science.gov (United States)

    Holmes, Richard R.; Mckechnie, Timothy N.

    1989-01-01

    Currently, protective plasma spray coatings are applied to space shuttle main engine turbine blades of high-performance nickel alloys by an air plasma spray process. Originally, a ceramic coating of yttria-stabilized zirconia (ZrO2.12Y2O3) was applied for thermal protection, but was removed because of severe spalling. In vacuum plasma spray coating, plasma coatings of nickel-chromium-aluminum-yttrium (NiCrAlY) are applied in a reduced atmosphere of argon/helium. These enhanced coatings showed no spalling after 40 MSFC burner rig thermal shock cycles between 927 C (1700 F) and -253 C (-423 F), while current coatings spalled during 5 to 25 test cycles. Subsequently, a process was developed for applying a durable thermal barrier coating of ZrO2.8Y2O3 to the turbine blades of first-stage high-pressure fuel turbopumps utilizing the enhanced NiCrAlY bond-coating process. NiCrAlY bond coating is applied first, with ZrO2.8Y2O3 added sequentially in increasing amounts until a thermal barrier coating is obtained. The enchanced thermal barrier coating has successfully passed 40 burner rig thermal shock cycles.

  18. Characterization and High-Temperature Oxidation Behavior of Cold-Sprayed Ni-20Cr and Ni-50Cr Coatings on Boiler Steels

    Science.gov (United States)

    Bala, Niraj; Singh, Harpreet; Prakash, Satya

    2011-11-01

    Microstructure and mechanical properties of cold-spray coatings are usually required in order to explore the potential industrial application of the latter. This article demonstrates the successful formulation of Ni-20Cr and Ni-50Cr coatings on two boiler steels, namely, SAE 213-T22 and SA 516 steel by cold-spray process. The microstructure, coating thickness, phase formation, and microhardness properties of the coatings were evaluated. The coatings were subjected to cyclic heating and cooling cycles at an elevated temperature of 1173.15 K (900 °C) to ascertain their high-temperature oxidation behavior. Moreover, these cyclic exposures can give useful information regarding the adhesion of the coatings with the substrate steels. Of all the coatings, the Ni-50Cr coating on SA 516 steel had a maximum average hardness value of 469 Hv. As observed from the surface field emission-scanning electron microscopy (FE-SEM) analysis, the coatings were found to have nearly dense microstructure with the sprayed particles in interlocked positions. It was concluded that the cold-spray process is suitable for spraying the preceding powders onto the given boiler steels to produce nearly dense and low oxide coatings. The coatings, in general, were found to follow the parabolic rate of oxidation and were successful in maintaining their surface contact with their respective substrate steels.

  19. High-Temperature Erosion of HVOF Sprayed Cr3C2-NiCr Coating and Mild Steel for Boiler Tubes

    Science.gov (United States)

    Yang, Guan-Jun; Li, Chang-Jiu; Zhang, Shi-Jun; Li, Cheng-Xin

    2008-12-01

    The comparison of the high-temperature erosion behavior of a High-velocity oxyfuel (HVOF) sprayed Cr3C2-NiCr coating with mild steel for circulating fluidized bed boiler tubes was investigated. Results showed that the erosion rate of the mild steel at 800 °C was four times that at 300 °C at an erosion angle of 30°. However, the erosion rate of the HVOF sprayed Cr3C2-NiCr coating was not influenced by the temperature in the range of 300-800 °C. It was found that the erosion resistance of HVOF sprayed Cr3C2-NiCr coating was more than three times higher than that of the mild steel at 700-800 °C. In addition to the ploughing on the coating surface, the cracking along splat interfaces in the coating was clearly observed on the cross-sectional microstructure. The results indicate that the erosion performance of the HVOF sprayed Cr3C2-NiCr coating is controlled by the cohesion between splats and can be further enhanced by improving splat cohesion.

  20. Effect of pores on the micromechanics of plasma-sprayed Cr3C2-NiCr coating in the nanoindentation testing

    Science.gov (United States)

    Zhang, Yongang; Wang, Yinzhen; Feng, Tao; Sun, Yongxing; Dong, Junzhe; Gao, Wei

    2017-07-01

    The elastoplastic properties of plasma-sprayed Cr3C2-NiCr coatings were obtained through the dimension analysis and inverse analysis by combining the experimental nanoindentation tests and numerical modeling. The digital image processing technique was used to extract the pore distribution inside the coatings based on the actual microstructure. Finally, the effect of pore distribution on the coating residual stress during nanoindentation process was analyzed through simulations. The anisotropic pore microstructure shows different mechanical responses and stress propagation behaviors during nanoindentation process. The elastic modulus of the coating demonstrates anisotropy along the spraying direction and the transverse directions due to the presence of pores.

  1. Effect of TiB2 Additives on Wear Behavior of NiCrBSi-Based Plasma-Sprayed Coatings

    Directory of Open Access Journals (Sweden)

    Oleksandr UMANSKYI

    2016-05-01

    Full Text Available The influence of titanium diboride additives on microstructure and wear-resistance of NiCrBSi thermally sprayed coatings deposited on a steel substrate has been studied. NiCrBSi-based composite powders with 10, 20, 40 wt.% TiB2 particles content were produced. The structure of NiCrSiB-TiB2 coatings consists of TiB2 and CrB grains distributed in Ni-based matrix. The wear-resistance of NiCrSiB-TiB2 plasma sprayed coatings in dry sliding conditions against the same coating using pin-on-disk tester. It was determined that the amount of titanium diboride particles in  NiCrBSi-based coatings influences essentially on the wear  resistance and wear mechanism. The NiCrBSi-based plasma sprayed coatings containing 20 wt. % of TiB2 possess the highest wear resistance due to the realization of mechano-oxidational wear mechanism.DOI: http://dx.doi.org/10.5755/j01.ms.22.1.7307

  2. Supersonic Plasma Spray Deposition of CoNiCrAlY Coatings on Ti-6Al-4V Alloy

    Science.gov (United States)

    Caliari, F. R.; Miranda, F. S.; Reis, D. A. P.; Essiptchouk, A. M.; Filho, G. P.

    2017-06-01

    Plasma spray is a versatile technology used for production of environmental and thermal barrier coatings, mainly in the aerospace, gas turbine, and automotive industries, with potential application in the renewable energy industry. New plasma spray technologies have been developed recently to produce high-quality coatings as an alternative to the costly low-pressure plasma-spray process. In this work, we studied the properties of as-sprayed CoNiCrAlY coatings deposited on Ti-6Al-4V substrate with smooth surface ( R a = 0.8 μm) by means of a plasma torch operating in supersonic regime at atmospheric pressure. The CoNiCrAlY coatings were evaluated in terms of their surface roughness, microstructure, instrumented indentation, and phase content. Static and dynamic depositions were investigated to examine their effect on coating characteristics. Results show that the substrate surface velocity has a major influence on the coating properties. The sprayed CoNiCrAlY coatings exhibit low roughness ( R a of 5.7 μm), low porosity (0.8%), excellent mechanical properties ( H it = 6.1 GPa, E it = 155 GPa), and elevated interface toughness (2.4 MPa m1/2).

  3. The formation model of Ni-Cr oxides on NiCoCrAlY-sprayed coating

    Energy Technology Data Exchange (ETDEWEB)

    Liang, G.Y., E-mail: gyliang@mail.xjtu.edu.cn [Department of Material Physics, MOE Key Laboratory for Nonequilibrium Synthesis and Modulation of Condensed Matter, School of Science, Xi' an Jiaotong University, Xi' an 710049 (China); Zhu, C.; Wu, X.Y.; Wu, Y. [Department of Material Physics, MOE Key Laboratory for Nonequilibrium Synthesis and Modulation of Condensed Matter, School of Science, Xi' an Jiaotong University, Xi' an 710049 (China)

    2011-05-15

    The atomic arrangement and distribution of oxides (Cr{sub 2}O{sub 3}, NiCr{sub 2}O{sub 4} and NiO) on the sprayed-NiCoCrAlY coating after oxidation are analyzed. The formation and the growth model of Ni-Cr oxide phases are discussed according to the matching relationship between atoms. The outline character and a scale of spinel NiCr{sub 2}O{sub 4} are discussed. The results show that Cr atoms can form two close-packed arrangements in the crystal plane of Cr{sub 2}O{sub 3} perpendicular to <0 0 1> orientation. The atomic spacing in the first arrangement corresponds to double that of Ni/Ni{sub 3}Al in {l_brace}1 1 1{r_brace} crystal face. This suggests that Ni/Ni{sub 3}Al is the substrate for Cr{sub 2}O{sub 3} to grow along <0 0 1> direction. The lattice mismatch between Cr{sub 2}O{sub 3} and Ni/Ni{sub 3}Al is less than that of Al{sub 2}O{sub 3}, which indicates that Cr{sub 2}O{sub 3} is easier to form than Al{sub 2}O{sub 3} during the oxidation process. The atomic spacing in another close-packed arrangement of Cr{sub 2}O{sub 3} perpendicular to <0 0 1> orientation is approximately equal to that of Ni or Cr in the plane of NiCr{sub 2}O{sub 4} and NiO perpendicular to <1 1 1> orientation. So Cr{sub 2}O{sub 3} can be the substrate for NiCr{sub 2}O{sub 4} and NiO to grow in the <0 0 1> direction. NiCr{sub 2}O{sub 4} and NiO can grow directly along the <1 1 1> orientation on each other. NiCr{sub 2}O{sub 4} can grow outward in the planes of Cr{sub 2}O{sub 3} perpendicular to <0 0 1> and grow inward along <1 1 1> orientation of NiO.

  4. Influence of Processing Parameters on Residual Stress of High Velocity Oxy-Fuel Thermally Sprayed WC-Co-Cr Coating

    Science.gov (United States)

    Gui, M.; Eybel, R.; Asselin, B.; Radhakrishnan, S.; Cerps, J.

    2012-10-01

    Residual stress in high velocity oxy-fuel (HVOF) thermally sprayed WC-10Co-4Cr coating was studied based on design of experiment (DOE) with five factors of oxygen flow, fuel gas hydrogen flow, powder feed rate, stand-off distance, and surface speed of substrate. In each DOE run, the velocity and temperature of in-flight particle in flame, and substrate temperature were measured. Almen-type N strips were coated, and their deflections after coating were used for evaluation of residual stress level in the coating. The residual stress in the coating obtained in all DOE runs is compressive. In the present case of HVOF thermally sprayed coating, the residual stress is determined by three types of stress: peening, quenching, and cooling stress generated during spraying or post spraying. The contribution of each type stress to the final compressive residual stress in the coating depends on material properties of coating and substrate, velocity and temperature of in-flight particle, and substrate temperature. It is found that stand-off distance is the most important factor to affect the final residual stress in the coating, following by two-factor interaction of oxygen flow and hydrogen flow. At low level of stand-off distance, higher velocity of in-flight particle in flame and higher substrate temperature post spraying generate more peening stress and cooling stress, resulting in higher compressive residual stress in the coating.

  5. Effect of vacuum heat treatment on microstructure and microhardness of cold sprayed Cu-4Cr-2Nb alloy coating

    Institute of Scientific and Technical Information of China (English)

    LI Wen-ya; GUO Xue-ping; L. DEMBINSKI; LIAO Han-lin; C.CODDET

    2006-01-01

    The effect of vacuum heat treatment on the microstructure and microhardness of cold-sprayed Cu-4%Cr-2%Nb alloy coating was investigated. The heat treatment was conducted under the temperatures from 250 ℃ to 950 ℃ with a step of 100 ℃ for 2 h. It was found that a dense thick Cu-4Cr-2Nb coating could be formed by cold spraying. After heat treatment,a Cr2Nb phase was uniformly distributed in the matrix,which was transferred from the gas-atomized feedstock. A little grain growth of Cr2Nb phase was observed accompanying with the healing-up of the incomplete interfaces between the deposited particles at the elevated temperatures. The coating microhardness increases a little with increasing the temperature to 350 ℃,and then decreases with further increasing temperature up to 950 ℃. This fact can be attributed to the microstructure evolution during the heat treatment.

  6. Comparative High-Temperature Corrosion Behavior of Ni-20Cr Coatings on T22 Boiler Steel Produced by HVOF, D-Gun, and Cold Spraying

    Science.gov (United States)

    Kaushal, Gagandeep; Bala, Niraj; Kaur, Narinder; Singh, Harpreet; Prakash, Satya

    2014-01-01

    To protect materials from surface degradations such as wear, corrosion, and thermal flux, a wide variety of materials can be deposited on the materials by several spraying processes. This paper examines and compares the microstructure and high-temperature corrosion of Ni-20Cr coatings deposited on T22 boiler steel by high velocity oxy-fuel (HVOF), detonation gun spray, and cold spraying techniques. The coatings' microstructural features were characterized by means of XRD and FE-SEM/EDS analyses. Based upon the results of mass gain, XRD, and FE-SEM/EDS analyses it may be concluded that the Ni-20Cr coating sprayed by all the three techniques was effective in reducing the corrosion rate of the steel. Among the three coatings, D-gun spray coating proved to be better than HVOF-spray and cold-spray coatings.

  7. The influences of heat treatments and interdiffusion on the adhesion of plasma-sprayed NiCrAlY coatings

    Energy Technology Data Exchange (ETDEWEB)

    Richard, C.S. [Universite de Technologie de Compiegne (France). Departement de Genie Mecanique; Beranger, G. [Universite de Technologie de Compiegne (France). Departement de Genie Mecanique; Lu, J. [Universite de Technologie de Troyes, Departement de Genie des Systemes Mecaniques, 10000, Troyes (France); Flavenot, J.F. [Centre Technique des Industries Mecaniques (CETIM), Departement Materiaux, 60306 Senlis (France)

    1996-07-01

    Most coatings are applied with a specific aim in mind, such as improving the base material resistance to corrosion or wear, or providing a barrier against high temperatures. These aims can obviously only be achieved if the coating is properly bonded to the substrate. This study is focused on a NiCrAlY metallic bonding layer and its adhesion on to nickel-based superalloy substrate. It also looks at the influence of different spraying methods (atmospheric plasma spraying and vacuum plasma spraying) and the influence of a post-heat treatment on adhesion of the coatings. In order to determine adherence, a Vickers indentation test was performed at the substrate/coating interface. In each case, the residual stresses were evaluated by a step-by-step hole drilling method and these were taken into account in assessing the adhesion parameters. The results were supplemented by a microstructural study of the interface. (orig.)

  8. Laser Remelting of Plasma Sprayed NiCrA1Y and NiCrAlY-A12O3 Coatings

    Institute of Scientific and Technical Information of China (English)

    2001-01-01

    Two types of plasma sprayed coatings (NiCrAIY and NiCrAIY-AI2O3) were remelted by a 5 kW cw CO2 laser. With increasing laser power and decreasing traverse speed in the ranges of 200~700 W and 5~30 mm/s respectively, the melted track grew in width and depth. In the optimum range of laser parameters, a homogeneous remelted layer without voids, cavities, unmelted particles and microcracks was formed. On the surface of remelted layers, AI2O3 and YAIO3 were detected.As a result of isothermal oxidation tests, weight gains of laser remelted coatings were obviously lower than that only plasma sprayed, especially laser remelted NiCrAIY-AI2O3 coatings. The effects of laser remelting and incorporation of Al2O3 second phase in NiCrAIY matrix on high temperature oxidation resistance were discussed.

  9. Microstructural features and properties of plasma sprayed YPSZ/NiCrAlY thermal barrier coating (TBC)

    Institute of Scientific and Technical Information of China (English)

    孙大谦; 王文权; 宣兆志; 宫文彪

    2004-01-01

    The plasma sprayed thermal barrier coating (TBC) consists of NiCrAlY bond coating and yttria partially stabilized zirconia (YPSZ) top coating. NiCrAlY coating mainly contains Ni solid solution with face centered cubic lattice, Al2O3 oxides and pores. The most obvious feature of YPSZ coating with tetragonal zirconia is a lot of vertical microcracks in this coating. The thermal insulation capability of the TBC increased with an increase in YPSZ coating thickness, the temperature drop across the TBC increasing from 60℃ to 92℃ with increasing YPSZ coating thickness with increasing YPSZ coating thickness and cracks initiated mainly in original vertical microcrack tips of the YPSZ coating and propagated not only along YPSZ coating / NiCrAlY coating interface but also through into two stages: transient oxidation stage with rapid oxidation rate and steady oxidation stage with slow oxidation. Their transition time was favorable to increase YPSZ coating toughness and to decrease the pores and oxides of the TBC system for improving thermal shock resistance and oxidation resistance of the TBC.

  10. Research Into Ni-Cr-Si-B Coating Sprayed Onto Aluminium Substrate Using the Method of Plasma Spray

    Directory of Open Access Journals (Sweden)

    Raimonda Lukauskaitė

    2012-12-01

    Full Text Available The article deals with Ni base coatings deposited on aluminium substrate applying the method of plasma spray. The purpose of the conducted research is to improve the physical and mechanical properties of coatings on the surface of aluminium alloy work pieces. Spraying on aluminium alloys encounters serious problems, and therefore this work analyses the ways to make the situation more favourable. Before spraying, the surfaces of substrates were modified employing chemical and mechanical pre-treatment methods. The aim of pre-treating aluminium alloys was to remove oxide layers from the aluminium surface. Coating microstructures and porosity were characterised applying optical microscopy. Differences in the roughness of pre-treated surfaces have been determined referring to profilometry. The paper investigates the influence of the adhesion of plasma spray coatings on aluminium surface pretreatment. Microhardness technique was applied for measuring the hardness of coatings. The study also describes and compares the mechanical properties of Ni base coatings deposited on different pre-treated aluminium substrates using plasma spray.Article in Lithuanian

  11. Research Into Ni-Cr-Si-B Coating Sprayed Onto Aluminium Substrate Using the Method of Plasma Spray

    Directory of Open Access Journals (Sweden)

    Raimonda Lukauskaitė

    2013-02-01

    Full Text Available The article deals with Ni base coatings deposited on aluminium substrate applying the method of plasma spray. The purpose of the conducted research is to improve the physical and mechanical properties of coatings on the surface of aluminium alloy work pieces. Spraying on aluminium alloys encounters serious problems, and therefore this work analyses the ways to make the situation more favourable. Before spraying, the surfaces of substrates were modified employing chemical and mechanical pre-treatment methods. The aim of pre-treating aluminium alloys was to remove oxide layers from the aluminium surface. Coating microstructures and porosity were characterised applying optical microscopy. Differences in the roughness of pre-treated surfaces have been determined referring to profilometry. The paper investigates the influence of the adhesion of plasma spray coatings on aluminium surface pretreatment. Microhardness technique was applied for measuring the hardness of coatings. The study also describes and compares the mechanical properties of Ni base coatings deposited on different pre-treated aluminium substrates using plasma spray.Article in Lithuanian

  12. The Comparative Effect of Sugarcane Juice on the Abrasion-Corrosion Behavior of Fe-Cr-B Electric Arc Sprayed and Fe-Cr-C Weld Coatings

    Science.gov (United States)

    Buchanan, Vernon E.

    2012-02-01

    Abrasion-corrosion tests were conducted on two commonly Fe-Cr-C shielded metal arc welding (SMAW) hardfacings used in the sugar industry and an arc sprayed Fe-Cr-based coating. The tests were performed on a modified block-on-ring tester with the coatings sliding against compressed sugarcane fiber in the presence of abrasive slurry. The findings showed that, in the presence of sugarcane juice and sand slurry, the SMAW coatings had similar wear performance while the abrasive wear of the arc-sprayed coating was superior to the SMAW coatings. In the presence of a neutral solution, the material loss from the arc-sprayed coating was similar to that obtained in the sugarcane juice while the SMAW coatings showed a marked decrease; this demonstrated that the arc-sprayed coating was more desirable in an abrasive-corrosion environment. The study also showed that the resistance to material does not follow the expected trend, in which wear resistance increases with increasing hardness.

  13. Determination of characteristics of erosion wear of grade 15Kh11MF steel with the Cr-CrC ion-plasma sprayed coating

    Science.gov (United States)

    Seleznev, L. I.; Mednikov, A. F.; Tkhabisimov, A. B.; Ryzhenkov, A. V.; Kachalin, G. V.; Zilova, O. S.

    2016-06-01

    Results of investigations of the influence of a Cr-CrC ion-plasma sprayed protective coating on characteristics and the intensity of erosion wear of grade 15Kh11MF steel at a gas-abrasive flow incidence angle of 30° and an experimental specimen (target) surface temperature of 550°C are presented. The Cr-CrC ion-plasma sprayed coating was formed in a Gefest vacuum installation by magnetron deposition. Investigations of the formed coating were carried out using a research and experimental facility complex that provided the study of the composition and structure of the coating, measurement of its thickness, roughness, microhardness, and determination of its relative resistance at the combined action of the gas-abrasive flow and high temperatures. The Cr-CrC coating with a thickness of 6.5 ± 0.3 μm has a finegrained structure with grains with dimensions of 20-40 nm and contains layers of chromium and chromium carbide. The main coating element is chromium. Its content in carbide layers is 89.4-91.9% at a carbon content of 6.8-9.5%. The coating microhardness is H 0.05 = 1350 ± 50 HV. The maximum wear of the 15Kh11MF steel target is observed at the angle of the gas-abrasive flow incidence that is close to 30° (30 7°). With this incidence angle and a target surface temperature of 550°C, the Cr-CrC coating extends the term to the surface failure and the appearance of a clear abrasive trace no less than four times. The coating failure has a local character, i.e., the target surface forms islands with the coating, between which the intensive wear of the base material occurs.

  14. Development of Erosion-Corrosion-Resistant Cold-Spray Nanostructured Ni-20Cr Coating for Coal-Fired Boiler Applications

    Science.gov (United States)

    Kumar, M.; Singh, H.; Singh, N.; Chavan, N. M.; Kumar, S.; Joshi, S. V.

    2015-12-01

    The erosion-corrosion (E-C) behavior of a cold-spray nanostructured Ni-20Cr coating was studied under cyclic conditions in a coal-fired boiler. This study was done for 15 cycles (1500 h), in which each cycle comprised 100 h of heating in the boiler environment, followed by 1 h of cooling under ambient air conditions. The E-C extent was evaluated in terms of thickness loss data of the samples. The eroded-corroded samples were characterized using XRD, SEM/EDS, and x-ray mapping analyses. The nanostructured coating offered excellent E-C protection to boiler tube material (SA 516 steel) under harsh live conditions of the boiler. This E-C resistance offered by investigated coating may be attributed to the presence of protective NiO and Cr2O3 phases in its oxide scale and its superior as-sprayed microhardness.

  15. Electrochemical corrosion and metal ion release from Co-Cr-Mo prosthesis with titanium plasma spray coating.

    Science.gov (United States)

    Reclaru, Lucien; Eschler, Pierre-Yves; Lerf, Reto; Blatter, Andreas

    2005-08-01

    The corrosion behavior of CoCrMo implants with rough titanium coatings, applied by different suppliers by either sintering or vacuum plasma spraying, has been evaluated and compared with uncoated material. The open-circuit potential, corrosion current and polarization resistance were determined by electrochemical techniques. The Co, Cr and Ti ions released from the samples into the electrolyte during a potentiostatic extraction technique were analyzed using ICP-MS. The Ti coatings from the different suppliers showed a different porous morphology, and the implants exhibited a distinct corrosion activity, underlining the importance of the coating process parameters. Among the titanium coated samples, the one with the sintered overcoat turned out to be the most resistant. Yet, on an absolute scale, they all showed a corrosion resistance inferior to that of uncoated CoCrMo or wrought titanium.

  16. Microstructure and Properties of HVOF-Sprayed NiCrAlY Coatings Modified by Rare Earth

    Science.gov (United States)

    Chen, S. F.; Liu, S. Y.; Wang, Y.; Sun, X. G.; Zou, Z. W.; Li, X. W.; Wang, C. H.

    2014-06-01

    Rare earth (RE)-modified NiCrAlY powders were prepared by ultrasonic gas atomization and deposited on stainless steel substrate by high-velocity oxygen fuel spraying. The effects of the RE on the microstructure, properties, and thermal shock resistance of the NiCrAlY coatings were investigated. The results showed that the NiCrAlY powders were refined and distributed uniformly after adding RE, while the number of unmelted particles in the coatings was reduced. Moreover, the RE-modified coatings showed improved microhardness and distribution uniformity. The microhardness of the coating reached a maximum after adding 0.9 wt.% RE, being 34.4 % higher than that of coatings without RE. The adhesive strength increased and reached a maximum after adding 0.6 wt.% RE, being 18.8 % higher than that of coatings without RE. Excessive RE decreased the adhesive strength. The thermal cycle life of NiCrAlY coatings increased drastically with RE addition. The coating with 0.9 wt.% RE showed optimum thermal shock resistance, being 21.2 % higher than that of coatings without RE.

  17. Evaluation of Thermocyclic Oxidation Behavior of HVOF-Sprayed NiCrFeSiB Coatings on Boiler Tube Steels

    Science.gov (United States)

    Ramesh, M. R.; Prakash, S.; Nath, S. K.; Sapra, Pawan Kumar; Krishnamurthy, N.

    2011-09-01

    High velocity oxy-fuel (HVOF) spray process has grown into a well-accepted industrial technology for obtaining coatings resistant to significant surface degradation processes. In the present study, HVOF process was used to deposit Ni-based hardfacing NiCrFeSiB alloy powder on kinds of boiler tube steels designated as SA210 grade-A1, SA213-T11, and SA213-T22. The microstructures and several properties of the as-sprayed coatings have been investigated. Thermocyclic oxidation studies were performed in static air at 900 °C. NiCrFeSiB-coated steels showed slow oxidation kinetics and considerably lower weight gains than that of uncoated steels. The superior performance of NiCrFeSiB coatings can be attributed to continuous and protective thin oxide scale of amorphous SiO2 and Cr2O3 formed on the surface of the oxidized coatings. The combined technique of x-ray diffraction, scanning electron microscopy, energy dispersive x-ray analysis, and electron probe microanalysis are used to characterize reaction products of the oxidized surfaces.

  18. Tribological Properties of WC-Co/NiCrBSi and Mo/NiCrBSi Plasma Spray Coatings under Boundary Lubrication Conditions

    Directory of Open Access Journals (Sweden)

    A. Vencl

    2017-06-01

    Full Text Available The tungsten carbide based WC-Co/NiCrBSi (50/50 and molybdenum based Mo/NiCrBSi (75/25 coatings were investigated under boundary lubricated sliding conditions, and their tribological properties were analysed and compared. These two coatings are in service for a long time, but there are very few papers dealing with their tribological properties, especially in lubricated sliding conditions. The NiCrBSi self-fluxing alloy is one of the popularly used materials for thermal sprayed coating, with relatively high hardness, reasonable wear resistance and high temperature corrosion. Tungsten carbide (WC is one of the most widely used commercial hard coating materials, and is added to the NiCrBSi coating to improve its hardness and wear resistance. Molybdenum (Mo is added to the NiCrBSi coating to reduce its coefficient of friction, i.e. to improve its dry sliding wear resistance. The results showed that WC-Co/NiCrBSi coating was more wear resistant, but caused higher wear of the counter-body material. Coefficients of friction were similar for both coatings.

  19. Erosion behaviour of WC–10Co–4Cr coating on 23-8-N nitronic steel by HVOF thermal spraying

    Energy Technology Data Exchange (ETDEWEB)

    Kumar, Avnish, E-mail: avnishmnit@gmail.com [Department of Metallurgical and Materials Engineering, Malaviya National Institute of Technology, Jaipur, Rajasthan 302017 (India); Sharma, Ashok, E-mail: ashok.mnit12@gmail.com [Department of Metallurgical and Materials Engineering, Malaviya National Institute of Technology, Jaipur, Rajasthan 302017 (India); Goel, S.K., E-mail: skgoel@splsteel.com [Star Wire India Ltd., Ballabgarh, Haryana 121404 (India)

    2016-05-01

    Highlights: • WC–10Co–4Cr powder was HVOF sprayed on cast and solution treated 23-8-N nitronic steel. • Coated solution treated 23-8-N steel shows homogeneous microstructure, less decarburization and high fracture toughness as compared to coated cast steel. • Erosion behaviour of both coated steels was evaluated at two different impact angles. • Coated solution treated 23-8-N nitronic steel exhibits higher erosion resistance as compared to coated cast steel. • Key erosion resistance factors: homogeneous and well-bonded structure, high fracture toughness, optimum substrate properties. - Abstract: WC–10Co–4Cr coating was deposited by high-velocity oxy-fuel (HVOF) process on cast and solution treated (1220 °C/150 min) 23-8-N nitronic steel substrates. Solution treated substrate has shown higher toughness, ductility and impact energy with a marginal reduction in hardness as compared to cast substrate. This influence the coating deposition efficiency and erosion behaviour. Erosion resistance of coatings was evaluated by air jet erosion tester on two different impact angles (30° and 90°). Phases, microstructure and eroded surface of the coating were characterised by X-ray diffraction (XRD) analysis and field-emission scanning electron microscopy (FESEM) respectively. It is observed that coating on solution treated substrate was superior to cast substrate. The reason being that coating has dense and well-bonded structure with low porosity, less decarburization and inter-splat oxidation. Higher erosion resistance of coated solution treated 23-8-N nitronic steel was attributed to combination of high fracture toughness and hardness of coating including optimum mechanical properties of the substrate. FESEM analysis reveals that erosion response of WC–10Co–4Cr coating also dependent on the relative size of the impact crater with respect to the WC grain size. Coating is removed by combined mode of ductile and brittle erosion.

  20. Role of HVOF-spray NiCr coatings to control high temperature oxidation of some boiler steels

    Energy Technology Data Exchange (ETDEWEB)

    Kaushal, G. [RIMT-Institute of Engineering and Technology, Mandi Gobind Garh (India); Singh, H. [BBSB Engineering College, Fatehgarh Sahib (India); Prakash, S. [Indian Inst. of Technology, Roorkee (India)

    2008-07-01

    A study was carried out to determine the role of HVOF-spray Ni-20Cr coatings to enhance high temperature oxidation resistance of T22 and 347H boiler steels. Ni-20Cr coatings were deposited on the boiler steels. Subsequently high temperature oxidation behavior of these coatings was investigated by laboratory tests at an elevated temperature of 900 C under cyclic conditions.These coatings were also subjected to a boiler environment at an elevated temperature of 700 C under cyclic conditions to ascertain their erosion-corrosion behaviour. Thermogravimetric data was taken after each cycle to formulate the oxidation, as well as, erosion-corrosion kinetics. The specimens were also physically examined after each cycle to notice any macrographic physical changes, spallation tendency of their oxide scales etc. The exposed specimens were examined using scanning electron microscopy and Energy Dispersive Spectroscopy (SEM/EDS) analysis. It was observed that oxidation rate was subsequently low in the coated substrates as compare to uncoated steels. It was observed that Ni-20Cr coating on 347H boiler substrate showed the maximum oxidation resistance. Moreover, both the steels showed better resistance to erosion-corrosion in actual boiler conditions after the application of Ni-20Cr coating. (orig.)

  1. High-Temperature Exposure Studies of HVOF-Sprayed Cr3C2-25(NiCr)/(WC-Co) Coating

    Science.gov (United States)

    Singh, Harpreet; Kaur, Manpreet; Prakash, Satya

    2016-08-01

    In this research, development of Cr3C2-25(NiCr) + 25%(WC-Co) composite coating was done and investigated. Cr3C2-25(NiCr) + 25%(WC-Co) composite powder [designated as HP2 powder] was prepared by mechanical mixing of [75Cr3C2-25(NiCr)] and [88WC-12Co] powders in the ratio of 75:25 by weight. The blended powders were used as feedstock to deposit composite coating on ASTM SA213-T22 substrate using High Velocity Oxy-Fuel (HVOF) spray process. High-temperature oxidation/corrosion behavior of the bare and coated boiler steels was investigated at 700 °C for 50 cycles in air, as well as, in Na2SO4-82%Fe2(SO4)3 molten salt environment in the laboratory. Erosion-corrosion behavior was investigated in the actual boiler environment at 700 ± 10 °C under cyclic conditions for 1500 h. The weight-change technique was used to establish the kinetics of oxidation/corrosion/erosion-corrosion. X-ray diffraction, field emission-scanning electron microscopy/energy-dispersive spectroscopy (FE-SEM/EDS), and EDS elemental mapping techniques were used to analyze the exposed samples. The uncoated boiler steel suffered from a catastrophic degradation in the form of intense spalling of the scale in all the environments. The oxidation/corrosion/erosion-corrosion resistance of the HVOF-sprayed HP2 coating was found to be better in comparison with standalone Cr3C2-25(NiCr) coating. A simultaneous formation of protective phases might have contributed the best properties to the coating.

  2. Comparative characteristic and erosion behavior of NiCr coatings deposited by various high-velocity oxyfuel spray processes

    Science.gov (United States)

    Sidhu, Hazoor Singh; Sidhu, Buta Singh; Prakash, S.

    2006-12-01

    The purpose of this study is to analyze and compare the mechanical properties and microstructure details at the interface of high-velocity oxyfuel (HVOF)-sprayed NiCr-coated boiler tube steels, namely ASTM-SA-210 grade A1, ASTM-SA213-T-11, and ASTM-SA213-T-22. Coatings were developed by two different techniques, and in these techniques liquefied petroleum gas was used as the fuel gas. First, the coatings were characterized by metallographic, scanning electron microscopy/energy-dispersive x-ray analysis, x-ray diffraction, surface roughness, and microhardness, and then were subjected to erosion testing. An attempt has been made to describe the transformations taking place during thermal spraying. It is concluded that the HVOF wire spraying process offers a technically viable and cost-effective alternative to HVOF powder spraying process for applications in an energy generation power plant with a point view of life enhancement and to minimize the tube failures because it gives a coating having better resistance to erosion.

  3. High-temperature oxidation studies of cold-sprayed Ni-20Cr and Ni-50Cr coatings on SAE 213-T22 boiler steel

    Science.gov (United States)

    Bala, Niraj; Singh, Harpreet; Prakash, Satya

    2009-05-01

    The high-temperature oxidation behavior of cold-sprayed Ni-20Cr and Ni-50Cr coatings on SAE 213-T22 boiler steel has been investigated at 900 °C in air under cyclic heating and cooling conditions for 50 cycles. The kinetics of oxidation of coated and bare boiler steel has been established with the help of weight change measurements. It was observed that all the coated and bare steels obeyed parabolic rate law of oxidation. X-ray diffraction, FE-SEM/EDAX and X-ray mapping techniques were used to analyse the oxidation products of the coated and uncoated boiler steel. The uncoated steel suffered corrosion in the form of intense spalling and peeling of its oxide scale, which was perhaps due to the formation of unprotective Fe 2O 3 oxide scale. Both the coatings showed better resistance to the air oxidation as compared to the uncoated steel. The Ni-50Cr coating was found to be more protective than the Ni-20Cr-coated steel. The formation of oxides and spinels of nickel and chromium may be contributing to the development of air oxidation resistance in the coatings.

  4. Hot Corrosion Behavior of Arc-Sprayed Highly Dense NiCr-Based Coatings in Chloride Salt Deposit

    Science.gov (United States)

    Qin, Enwei; Yin, Song; Ji, Hua; Huang, Qian; Liu, Zekun; Wu, Shuhui

    2017-03-01

    To make cities more environmentally friendly, combustible wastes tend to be incinerated in waste-to-energy power plant boilers. However, release of chlorine gas (Cl2) during incineration causes serious problems related to hot corrosion of boiler tubes and poses a safety threat for such plants. In this study, a pseudo-de Laval nozzle was employed in a twin-wire arc spray system to enhance the velocity of in-flight particles. Highly dense NiCr-based coatings were obtained using the modified nozzle gun. The coating morphology was characterized by optical microscopy and scanning electron microscopy, and hot corrosion testing was carried out in a synthetic molten chloride salt environment. Results showed that the dense NiCr-based coatings exhibited high resistance against corrosion by chlorine, which can be related to the typical splat lamellar microstructure and chemical composition as well as minor alloying elements such as Ti and Mo.

  5. Hot Corrosion Behavior of Arc-Sprayed Highly Dense NiCr-Based Coatings in Chloride Salt Deposit

    Science.gov (United States)

    Qin, Enwei; Yin, Song; Ji, Hua; Huang, Qian; Liu, Zekun; Wu, Shuhui

    2017-04-01

    To make cities more environmentally friendly, combustible wastes tend to be incinerated in waste-to-energy power plant boilers. However, release of chlorine gas (Cl2) during incineration causes serious problems related to hot corrosion of boiler tubes and poses a safety threat for such plants. In this study, a pseudo-de Laval nozzle was employed in a twin-wire arc spray system to enhance the velocity of in-flight particles. Highly dense NiCr-based coatings were obtained using the modified nozzle gun. The coating morphology was characterized by optical microscopy and scanning electron microscopy, and hot corrosion testing was carried out in a synthetic molten chloride salt environment. Results showed that the dense NiCr-based coatings exhibited high resistance against corrosion by chlorine, which can be related to the typical splat lamellar microstructure and chemical composition as well as minor alloying elements such as Ti and Mo.

  6. Tribological properties of La2O3 and CeO2 doped CoCrW coatings deposited by supersonic plasma spraying

    Institute of Scientific and Technical Information of China (English)

    2007-01-01

    A novel supersonic plasma spraying was used to prepare rare earth oxides doped CoCrW coatings. X-ray diffractometer, contact surface profiler, hardness tester, micro-friction and -wear tester and environmental scanning electron microscope equipped with energy dispersive X-ray spectroscopy were employed to investigate the phase structure, surface morphology, microhardness, friction and wear properties of the sprayed coatings. The results show that rare earth oxide doped coatings have high microhardness and excellent tribological properties. Furthermore, the friction and wear mechanisms of sprayed coatings are also discussed.

  7. Wear of Flame-Sprayed Ni-Cr-B-Si Powder Coating on Journal for Seal Contact

    Directory of Open Access Journals (Sweden)

    Hu Sheng-Yen

    2016-01-01

    Full Text Available Flame-sprayed techniques is used in this paper to coat Ni-Cr-B-Si powder on low-carbon steel or bearing steel materials of the journal surface. The wear tester is used to explore material properties of the binding capability, surface hardness, wear and friction within each layer depth. The normal force is applied in addition to the cladding layer by not only using bearing ball but also oil seal pieces, to explore rubber material of oil seal contact journal. In experiments to explore the material and processing conditions affect the microstructure and hardness of the cladding layer, and at the same hardness, surface roughness to affect the performance of the mill run.The results showed that spraying Ni-Cr-B-Si alloy powder in mild steel sheet to melt and run, cladding layer and the substrate has a uniform distribution of fine abrasive particles and binding effect, causing the substrate surface hardness (HRC about promotion 10 times. While, if sprayed Ni-Cr-B-Si alloy powder to steel panels bearing surface because the surface coated compact structure, can reduce the surface roughness and the coefficient of friction, and more improve the wear resistance of the cladding layer.

  8. Microstructure, Mechanical Properties, and Two-Body Abrasive Wear Behavior of Cold-Sprayed 20 vol.% Cubic BN-NiCrAl Nanocomposite Coating

    Science.gov (United States)

    Luo, Xiao-Tao; Yang, Er-Juan; Shang, Fu-Lin; Yang, Guan-Jun; Li, Chen-Xin; Li, Chang-Jiu

    2014-10-01

    20 vol.% cubic boron nitride (cBN) dispersoid reinforced NiCrAl matrix nanocomposite coating was prepared by cold spray using mechanically alloyed nanostructured composite powders. The as-sprayed nanocomposite coating was annealed at a temperature of 750 °C to enhance the inter-particle bonding. Microstructure of spray powders and coatings was characterized. Vickers microhardness of the coatings was measured. Two-body abrasive wear behavior of the coatings was examined on a pin-on-disk test. It was found that, in mechanically alloyed composite powders, nano-sized and submicro-sized cBN particles are uniformly distributed in nanocrystalline NiCrAl matrix. Dense coating was deposited by cold spray at a gas temperature of 650 °C with the same phases and grain size as those of the starting powder. Vickers hardness test yielded a hardness of 1063 HV for the as-sprayed 20 vol.% cBN-NiCrAl coating. After annealed at 750 °C for 5 h, unbonded inter-particle boundaries were partially healed and evident grain growth of nanocrystalline NiCrAl was avoided. Wear resistance of the as-sprayed 20 vol.% cBN-NiCrAl nanocomposite coating was comparable to the HVOF-sprayed WC-12Co coating. Annealing of the nanocomposite coating resulted in the improvement of wear resistance by a factor of ~33% owing to the enhanced inter-particle bonding. Main material removal mechanisms during the abrasive wear are also discussed.

  9. A comparative study on solid particle erosion behavior of plasma sprayed Cr2O3 coatings on 410 grade steel

    Science.gov (United States)

    Sreenivas Rao, K. V.; Girisha, K. G.; Eswar, Sushruta

    2016-09-01

    In the present investigation chromium oxide (Cr2O3) powder particles were used to deposit on 410 martensitic steel. Ni-Cr was used as bond coat. Erosion studies were directed on uncoated and also plasma sprayed steel examples at room temperature. The Erosion analyses were done utilizing an air-jet erosion test rig at a speed of 30 m/s by varying stand-off distance as per ASTM G-76. The stand-off distance considered were 10mm, 20mm, 30mm & 40mm. Silica sand particles of size 312μm was used as erodent. The surface morphologies were characterized using Scanning electron microscope (SEM) and presence of coating material was confirmed using energy dispersive X-ray analyzer (EDS). Vickers micro harness test was performed on surface of coated and un-coated substrates. It was observed that Cr2O3 Coated specimen exhibits better Erosion resistance when contrasted with uncoated substrates because of its enhanced property like micro hardness.

  10. Hot Corrosion Performance of AlO-CrO/NiCoCrAlYTa and AlO/NiCoCrAlYTa Coatings Deposited by Atmospheric Plasma Spraying

    Science.gov (United States)

    Tao, Chong; Wang, Lei; Cheng, Nailiang; Hu, Hengfa; Liu, Yang; Song, Xiu

    2016-04-01

    AlO-CrO/NiCoCrAlYTa and AlO/NiCoCrAlYTa coatings were deposited on 316L stainless steel substrate using atmospheric plasma spraying, respectively, in order to improve the oxidation and corrosion resistance. The hot corrosion performance of the coatings at 700 and 900 °C were studied, and the detailed microstructures and phase composition of the coatings were analyzed using x-ray diffraction, scanning electron microscope with energy dispersive spectrometer, and transmission electron microscope. The results show that both coatings are structurally featured by slatted layers, consisting of amorphous phase, Cr2O3, Ni3Al, and Al2O3. The hot corrosion resistance of AlO-CrO/NiCoCrAlYTa coating is better than that of AlO/NiCoCrAlYTa coating. This improvement is attributed to lower porosity and more compact Cr2O3 in AlO-CrO/NiCoCrAlYTa coating which performs better than Al2O3 in blocking further inward progress of corrosion and oxidization.

  11. Erosion-corrosion of as-plasma-sprayed and laser-remelted NiCrAlY bond coats in working conditions of a coal-fired boiler

    Energy Technology Data Exchange (ETDEWEB)

    Sidhu, B.S.; Prakash, S. [College of Engineering & Technology, Bathinda (India). Dept. of Mechanical Engineering

    2008-01-15

    Ni-22Cr-10Al-1Y plasma spray coating has been formulated on boiler tube steels. namely, low-carbon steel ASTM SA210-Grade A1. 1Cr-0.5Mo steel ASTM SA213-T-11, and 2.25Cr-1Mo steel ASTM SA213-T-22. The coated steels also have been laser-remelted using a Nd:YAG laser. The degradation behavior of as-sprayed and laser-remelted coatings have been evaluated in actual conditions in a coal-fired boiler for 1,000 h at 755{sup o}C. The laser remelting has been found to be effective to increase the degradation resistance of plasma-sprayed boiler steels. ASTM SA213-T-22-coated and laser-remelted steel has proved to be most effective in resistance to degrading species.

  12. Electrochemical Corrosion of HVOF-Sprayed NiCoCrAlY Coatings in CO2-Saturated Brine

    Science.gov (United States)

    Ruiz-Luna, H.; Porcayo-Calderon, J.; Alvarado-Orozco, J. M.; García-Herrera, J. E.; Martinez-Gomez, L.; Trápaga-Martínez, L. G.; Muñoz-Saldaña, J.

    2016-10-01

    The effect of pre-oxidation treatment and surface preparation of optimized NiCoCrAlY coatings deposited by high-velocity oxygen fuel (HVOF) spraying and exposed to a low-temperature corrosive environment is reported herein. Coatings with two surface finish conditions (as-sprayed and ground) were heat treated under two different oxygen partial pressures (air and argon). The electrochemical corrosion behavior was evaluated in CO2-saturated brine via potentiodynamic polarization, polarization resistance, and electrochemical impedance measurements. The results show that the grinding process and pre-oxidation treatment in argon enhanced growth and formation of α-Al2O3 scale. The potentiodynamic polarization results show that both pre-oxidation and surface treatment had a positive influence on the corrosion resistance of the coating. The reduction of the porosity and the formation of a dense, uniform, and adherent oxide scale through pre-oxidation treatment led to an increase of the corrosion resistance due to a decrease in active sites and blocking of diffusion of reactive species into the coating. However, according to the results, complete transformation from metastable alumina phases to α-Al2O3 in addition to formation and growth of dense α-Al2O3 is required to ensure full protection of the coating and base material over long periods.

  13. Electrochemical Corrosion of HVOF-Sprayed NiCoCrAlY Coatings in CO2-Saturated Brine

    Science.gov (United States)

    Ruiz-Luna, H.; Porcayo-Calderon, J.; Alvarado-Orozco, J. M.; García-Herrera, J. E.; Martinez-Gomez, L.; Trápaga-Martínez, L. G.; Muñoz-Saldaña, J.

    2016-08-01

    The effect of pre-oxidation treatment and surface preparation of optimized NiCoCrAlY coatings deposited by high-velocity oxygen fuel (HVOF) spraying and exposed to a low-temperature corrosive environment is reported herein. Coatings with two surface finish conditions (as-sprayed and ground) were heat treated under two different oxygen partial pressures (air and argon). The electrochemical corrosion behavior was evaluated in CO2-saturated brine via potentiodynamic polarization, polarization resistance, and electrochemical impedance measurements. The results show that the grinding process and pre-oxidation treatment in argon enhanced growth and formation of α-Al2O3 scale. The potentiodynamic polarization results show that both pre-oxidation and surface treatment had a positive influence on the corrosion resistance of the coating. The reduction of the porosity and the formation of a dense, uniform, and adherent oxide scale through pre-oxidation treatment led to an increase of the corrosion resistance due to a decrease in active sites and blocking of diffusion of reactive species into the coating. However, according to the results, complete transformation from metastable alumina phases to α-Al2O3 in addition to formation and growth of dense α-Al2O3 is required to ensure full protection of the coating and base material over long periods.

  14. High-Temperature Behavior of a High-Velocity Oxy-Fuel Sprayed Cr3C2-NiCr Coating

    Science.gov (United States)

    Kaur, Manpreet; Singh, Harpreet; Prakash, Satya

    2012-08-01

    High-velocity oxy-fuel (HVOF) sprayed coatings have the potential to enhance the high-temperature oxidation, corrosion, and erosion-corrosion resistance of boiler steels. In the current work, 75 pct chromium carbide-25 pct (nickel-20 pct chromium) [Cr3C2-NiCr] coating was deposited on ASTM SA213-T22 boiler steel using the HVOF thermal spray process. High-temperature oxidation, hot corrosion, and erosion-corrosion behavior of the coated and bare steel was evaluated in the air, molten salt [Na2SO4-82 pct Fe2(SO4)3], and actual boiler environments under cyclic conditions. Weight-change measurements were taken at the end of each cycle. Efforts were made to formulate the kinetics of the oxidation, corrosion, and erosion-corrosion. X-ray diffraction (XRD) and field-emission scanning electron microscopy (FE-SEM)/energy dispersive spectroscopy (EDS) techniques were used to analyze the oxidation products. The coating was found to be intact and spallation free in all the environments of the study in general, whereas the bare steel suffered extensive spallation and a relatively higher rate of degradation. The coating was found to be useful to enhance the high-temperature resistance of the steel in all the three environments in this study.

  15. Pengaruh NiCrAlY, Ni/Cr2O3/CrxCy Sebagai Variasi Bond Coat Dengan Penambahan Lapisan Al2O3 dan YSZ Pada Inconel 625 Terhadap Struktur Mikro Lapisan Menggunakan Metode Flame Spraying

    Directory of Open Access Journals (Sweden)

    Aprian Immanuel

    2017-01-01

    Full Text Available Thermal Barrier Coating (TBC berfungsi untuk mengurangi temperatur substrat serta meningkatkan daya tahannya terhadap korosi dan oksidasi. Pada penelitian ini, digunakan flame spraying dari variasi bond coat (Ni-Cr-Al-Y, (Ni/CrO3/CrXCY dan tanpa bond coat serta melapisi kembali lapisan bond coat dengan Al2O3 dan ZrO2 – 8%Y2O3 sebagai Thermal Barrier Coating untuk diteliti pengaruhnya terhadap struktur mikro lapisan yang terbentuk. Hasil flame spray diamati dengan SEM pada variasi bond coat NiCrAlY ditemukan beberapa serbuk dari material top coat dengan beberapa kondisi yaitu meleleh (melted, meleleh sebagian (semi melted, dan tidak meleleh (unmelted. Ditemukan poros yang merata hampir di seluruh permukaan sampel dan munculnya pengintian retak. Perbedaan sebelum dan sesudah perlakuan ada pada persebaran setiap unsur di setiap spesimen, dan lapisan oksida yang terbentuk pada seluruh variasi bond coat

  16. Formation Mechanisms, Structure, and Properties of HVOF-Sprayed WC-CoCr Coatings: An Approach Toward Process Maps

    Science.gov (United States)

    Varis, T.; Suhonen, T.; Ghabchi, A.; Valarezo, A.; Sampath, S.; Liu, X.; Hannula, S.-P.

    2014-08-01

    Our study focuses on understanding the damage tolerance and performance reliability of WC-CoCr coatings. In this paper, the formation of HVOF-sprayed tungsten carbide-based cermet coatings is studied through an integrated strategy: First-order process maps are created by using online-diagnostics to assess particle states in relation to process conditions. Coating properties such as hardness, wear resistance, elastic modulus, residual stress, and fracture toughness are discussed with a goal to establish a linkage between properties and particle characteristics via second-order process maps. A strong influence of particle state on the mechanical properties, wear resistance, and residual stress stage of the coating was observed. Within the used processing window (particle temperature ranged from 1687 to 1831 °C and particle velocity from 577 to 621 m/s), the coating hardness varied from 1021 to 1507 HV and modulus from 257 to 322 GPa. The variation in coating mechanical state is suggested to relate to the microstructural changes arising from carbide dissolution, which affects the properties of the matrix and, on the other hand, cohesive properties of the lamella. The complete tracking of the coating particle state and its linking to mechanical properties and residual stresses enables coating design with desired properties.

  17. A Combined Brazing and Aluminizing Process for Repairing Turbine Blades by Thermal Spraying Using the Coating System NiCrSi/NiCoCrAlY/Al

    Science.gov (United States)

    Nicolaus, M.; Möhwald, K.; Maier, H. J.

    2017-08-01

    The repair and maintenance of components in the aerospace industry play an increasingly important role due to rising manufacturing costs. Besides welding, vacuum brazing is a well-established repair process for turbine blades made of nickel-based alloys. After the coating of the worn turbine blade has been removed, the manual application of the nickel-based filler metal follows. Subsequently, the hot gas corrosion-protective coating is applied by thermal spraying. The brazed turbine blade is aluminized to increase the hot gas corrosion resistance. The thermal spray technology is used to develop a two-stage hybrid technology that allows shortening the process chain for repair brazing turbine blades and is described in the present paper. In the first step, the coating is applied on the base material. Specifically, the coating system employed here is a layer system consisting of nickel filler metal, NiCoCrAlY and aluminum. The second step represents the combination of brazing and aluminizing of the coating system which is subjected to a heat treatment. The microstructure, which results from the combined brazing and aluminizing process, is characterized and the relevant diffusion processes in the coating system are illustrated. The properties of the coating and the ramifications with respect to actual applications will be discussed.

  18. Carbide Dissolution/Carbon Loss as a Function of Spray Distance in Unshrouded/Shrouded Plasma Sprayed Cr3C2-NiCr Coatings

    Science.gov (United States)

    Matthews, S.

    2015-02-01

    Thermal spraying of Cr3C2-NiCr composites generates varying degrees of carbide dissolution into the Ni binder. During high-temperature exposure, the carbide dissolution zones precipitate high concentrations of small carbides which develop into finely structured networks. This raises the possibility of producing unique tailored carbide composite structures through the generation of controlled carbide dissolution and appropriate heat treatment. The first step in this process is to produce a supersaturated Ni-Cr-C solid solution from which the carbide phase could be precipitated. In a previous work, a broad range of plasma parameters were trialed to assess their effect on the degree of carbide dissolution at a fixed spray distance of 100 mm. The current two-part work builds on the most promising plasma parameters from those trials. In Part 1 of this two-part article series, the effect of spray distance on the extent of carbide dissolution and carbon loss during high energy plasma spraying was investigated. The effectiveness of solid shield and gas shrouding is contrasted, and the mechanisms by which they influence the degree of decarburization discussed.

  19. Corrosion Behavior of Thermally Sprayed NiCrBSi Coating on 16MnR Low-Alloy Steel in KOH Solution

    Science.gov (United States)

    Zeng, Q.; Sun, J.; Emori, W.; Jiang, S. L.

    2016-05-01

    NiCrBSi coatings were selected as protective material and air plasma-sprayed on 16MnR low-alloy steel substrates. Corrosion behavior of 16MnR substrates and NiCrBSi coatings in KOH solution were evaluated by polarization resistance ( R p), potentiodynamic polarization curves, electrochemical impedance spectroscopy, and immersion corrosion tests. Electrolytes were solutions with different KOH concentrations. NiCrBSi coating showed superior corrosion resistance in KOH solution compared with the 16MnR. Corrosion current density of 16MnR substrate was 1.7-13.0 times that of NiCrBSi coating in the given concentration of KOH solution. By contrast, R p of NiCrBSi coating was 1.2-8.0 times that of the substrate, indicating that the corrosion rate of NiCrBSi coating was much lower than that of 16MnR substrate. Capacitance and total impedance value of NiCrBSi coating were much higher than those of 16MnR substrate in the same condition. This result indicates that corrosion resistance of NiCrBSi coating was better than that of 16MnR substrate, in accordance with polarization results. NiCrBSi coatings provided good protection for 16MnR substrate in KOH solution. Corrosion products were mainly Ni/Fe/Cr oxides.

  20. Properties of plasma sprayed NiCrAlY + (ZrO2 + Y2 O3 ) coating on refractory steel surface

    Institute of Scientific and Technical Information of China (English)

    L(U) Tao; CHEN Fei; DING Hua-dong; HAN Dan-feng

    2005-01-01

    NiCrAlY + (ZrO2 + Y2 O3 ) thermal barrier coating was prepared on the surface of refractory steel 1Cr18Ni9Ti with plasma spraying technique. The phases and microstructure of the thermal barrier coating were determined by scanning electron microscopy(SEM) and X-ray diffraction(XRD). The results show that the bonding between thermal barrier coating and substrate is sound. The surface hardness of 1Cr18Ni9Ti reaches up to 1 000 HV, but that of substrate is only 300 HV. The patterns sprayed with CoNiCrAlY+(ZrO2+Y2 O3 ) ceramic coating have a good heat insulation effect at 800 ℃ for heat insulation temperature difference reaches 54 ℃, which increases the operating temperature and service life of refractory steel.

  1. HVOF sprayed WC-CoCr coatings on aluminum: tensile and tribological properties

    Science.gov (United States)

    Koutsomichalis, A.; Vardavoulias, M.; Vaxevanidis, N.

    2017-02-01

    This paper provides a comprehensive assessment of the tensile and sliding wear behaviour of WC-10Co4Cr agglomerated and sintered powder deposited on aluminum by Hyper Velocity Oxy-Fuel (HVOF) process. Microstructural analysis (SEM) identified grains of tungsten carbide (WC) in the metal matrix of the cobalt-chromium (Co-Cr). A transformation of the WC in the W2C phase was observed and decomposition of WC in the metal matrix. The HVOF WC-Co-Cr coating was found to decrease tensile strength of the aluminum substrate. Transverse cracks were observed to initiate on the coating surface, increasing rapidly with the increase in tensile strain and stopped on the coating-substrate interface causing decohesion. Tribological properties were examined using the pin-on-disk method under various loads. The friction coefficient rose abruptly at the start-up phase and stabilized at almost the same sliding distance independently of the applied load. Both the friction coefficient and the wear volume were found to increase with increasing applied load. Study of the wear mechanisms revealed surface micro-cracking and fragmentation of flattened coating layers with subsequent gradual pull out of the carbide particles.

  2. Karakterizacija WCCo/NiCrBSi prevlake otporne na habanje / Characterization of wear resistant plasma sprayed WCCo/NiCrBSi self-fluxing coatings

    Directory of Open Access Journals (Sweden)

    Mihailo R. Mrdak

    2010-04-01

    Full Text Available U radu su analizirani mikrostruktura, mehaničke i tribološke karakteristike (APS prevlake WCCoNiCrBSi koja se primenjuje za reparaciju cilindara nosne noge helikoptera. Tribološka procena prevlake određena je primenom tribometra blok-na-prstenu. Spregnuti materijalblokovi sa prevlakom ispitani su na okaljenom i poboljšanom čeličnom prstenu. Za ukupno odstojanje od 3000 m bili su konstantna brzina 0,5 m/s i opterećenje 400 N. Prednost primene ove prevlake je u značajnom produženju resursa delova uz smanjenje troškova eksploatacije i održavanja. / In this paper, the microstructural, mechanical and tribological properties of WCCoNiCrBSi thermal spray coatings, applied to repair the cylinders of helicopter nasal feet, were analyzed. The process used for coating deposition on steel substrate was the Atmospheric Plasma Spraying (APS.The plasma spray process is a procedure widely used for applying coatings with increased resistance to wear. The combination of WCCo and NiCrBSi powders produced coatings for the protection of metal parts exposed to wear abrasion, erosion and cavitation to 540°C. The WCCoNiCrBSi 50/50% powder is specially developed for the production of coatings of high cohesion and adhesive strength. The coatings are very dense, hard and smooth. Microstructures present in the layers are tungsten carbides and chromium layers that increase resistance to wear and abrasion. Powder is deposited on the substrate rugged with Al2O3. The substrates were heated at temperatures up to 200°C. Powder deposition was performed with the optimal deposition parameters The microstructure and micro hardness of the coating layer was investigated on the cross section of samples using the Pratt & Whitney standard. Micro hardness was tested using the Vickers scale with a load of 300g. The microstructure of the layers was investigated on an optical microscope (OM with a magnification of 400X. Testing of bond strength between coatings and substrates

  3. Improved Thermally Grown Oxide Scale in Air Plasma Sprayed NiCrAlY/Nano-YSZ Coatings

    Directory of Open Access Journals (Sweden)

    Mohammadreza Daroonparvar

    2013-01-01

    Full Text Available Oxidation has been considered as one of the principal disruptive factors in thermal barrier coating systems during service. So, oxidation behavior of thermal barrier coating (TBC systems with nanostructured and microstructured YSZ coatings was investigated at 1000∘C for 24 h, 48 h, and 120 h. Air plasma sprayed nano-YSZ coating exhibited a trimodal structure. Microstructural characterization also demonstrated an improved thermally grown oxide scale containing lower spinels in nano-TBC system after 120 h of oxidation. This phenomenon is mainly related to the unique structure of the nano-YSZ coating, which acted as a strong barrier for oxygen diffusion into the TBC system at elevated temperatures. Nearly continues but thinner Al2O3 layer formation at the NiCrAlY/nano-YSZ interface was seen, due to lower oxygen infiltration into the system. Under this condition, spinels formation and growth on the Al2O3 oxide scale were diminished in nano-TBC system compared to normal TBC system.

  4. The Surface Morphologies and Spectroscopy Analysis of VC Coatings on the Substrate of Cr12MoV Prepared by TD Process after Salt Spray

    Institute of Scientific and Technical Information of China (English)

    KONG Dejun; ZHOU Chaozheng; LONG Dan; WU Yongzhong

    2012-01-01

    The normal temperature corrosion of VC coating on the substrate of Cr12MoV prepared by TD process was tested in 5% NaCl aqueous solution,its surface morphologies and corrosion components after salt spray were observed with SEM and EDS,respectively,and the effects of salt spray on micro-structures of VC coating were analyzed.Moreover,the invalidation mechanism of VC coating after salt spray and its effect on substrate material were discussed.The experimental results shown that the uniformity and integrity of VC coating surface are destroyed by salt spray for 120 h,a large number of the pits are produced on the coating surface,and the coating falls off,which speeds corrosion breakage of its substrate; the oxidated film on its surface becomes rougher,broken and discontinuous,and falls off easily,which reduce the ability of resistance salt spray; the failure modes of VC coating after salt spray are expressed with falling off of oxidated film,stress concentration and pore effect and so on,the corrosion breakage of oxidated film is the corrosion result of deoxidization corrosion from oxygen and HCl produced by NaCl and vapor.

  5. Corrosion resistance of plasma sprayed NiCrAl + (ZrO2 + Y2O3 ) thermal barrier coating on 18 -8 steel surface

    Institute of Scientific and Technical Information of China (English)

    CHEN Fei; L(U) Tao; DING Hua-dong; ZHOU Hai; LIU Kai

    2005-01-01

    The corrosion resistance of NiCrAl +(ZrO2 + Y2 O3 )thermal barrier coating, formed with the plasma spraying technique, on the 18 - 8 steel surface was investigated. The phase structure and morphology of the coating were analyzed by means of X-ray diffraction(XRD) and scanning electron microscopy(SEM). The electrochemical corrosion behavior of the coating in 1.0 mol/L H2 SO4 solution was studied by using electrochemical measurement methods. The results show that the gradient plasma spraying coating is composed of the NiCrAlY primer coating and the (ZrO2 + Y2O3 ) top coating, and the coating thickness is 360 μm. The microhardness of coating reaches 1 100 HV. The corrosion resistance of the plasma sprayed coating of the 18 - 8 steel surface is about 5 times as great as that of the original pattern. The corrosion resistance of the coating is enhanced notably.

  6. Properties of Plasma and HVOF Sprayed Coatings

    Directory of Open Access Journals (Sweden)

    Wojciech Żórawski

    2012-11-01

    Full Text Available The work compares the properties of plasma and HVOF thermally sprayed coatings obtained by blending the NiCrBSi and Fe2O3 powders. The deposition was performed by means of the Plancer PN-120 and the Diamond Jet guns for plasma spraying and HVOF spraying respectively. The SEM (EDS method was employed to study the microstructure of the produced coatings. Although the blended powders differ in particle size, shape, and distribution, it is possible to obtain composite coatings with an NiCrBSi matrix containing iron oxides. Except for a different microstructure, plasma and HVOF coatings have a different phase composition, which was examined using the Bruker D-8 Advance diffractometer. Studies of the coatings wear and scuffing resistance showed that an optimal content of Fe2O3 is about 26 % for plasma sprayed coatings and 22.5 % for HVOF deposited coatings.

  7. HVOF- and HVAF-Sprayed Cr3C2-NiCr Coatings Deposited from Feedstock Powders of Spherical Morphology: Microstructure Formation and High-Stress Abrasive Wear Resistance Up to 800 °C

    Science.gov (United States)

    Janka, L.; Norpoth, J.; Trache, R.; Thiele, S.; Berger, L.-M.

    2017-08-01

    Chromium carbide-based coatings are commonly applied to protect surfaces against wear at high temperatures. This work discusses the influence of feedstock powder and spray torch selection on the microstructure and high-stress abrasion resistance of thermally sprayed Cr3C2-NiCr coatings. Four commercial feedstock powders with spherical morphology and different microstructures were deposited by different high-velocity spray processes, namely third-generation gas- and liquid-fueled HVOF torches and by the latest generation HVAF torch. The microstructures of the coatings were studied in the as-sprayed state and after various heat treatments. The high-stress abrasion resistance of as-sprayed and heat-treated coatings was tested at room temperature and at 800 °C. The study reveals that the selection of the spray torch mainly affects the room temperature abrasion resistance of the as-sprayed coatings, which is due to differences in the embrittlement of the binder phase generated by carbide dissolution. At elevated temperatures, precipitation and growth of secondary carbides yields a fast equalization of the various coatings microstructures and wear properties.

  8. Study of mechanical properties and high temperature oxidation behavior of a novel cold-spray Ni-20Cr coating on boiler steels

    Energy Technology Data Exchange (ETDEWEB)

    Kaur, Narinder [Semiconductor Materials and Device Laboratory, Department of Semiconductor Science, Dongguk University-Seoul, Seoul 100715 (Korea, Republic of); Kumar, Manoj [School of Mechanical, Materials & Energy Engineering, Indian Institute of Technology Ropar, Rupnagar, Punjab (India); Sharma, Sanjeev K.; Kim, Deuk Young [Semiconductor Materials and Device Laboratory, Department of Semiconductor Science, Dongguk University-Seoul, Seoul 100715 (Korea, Republic of); Kumar, S.; Chavan, N.M.; Joshi, S.V. [International Advanced Research Centre for Powder Metallurgy & New Materials (ARCI), Hyderabad 500005 (India); Singh, Narinder [Department of Chemistry, Indian Institute of Technology Ropar, Rupnagar, Punjab (India); Singh, Harpreet, E-mail: harpreetsingh@iitrpr.ac.in [School of Mechanical, Materials & Energy Engineering, Indian Institute of Technology Ropar, Rupnagar, Punjab (India)

    2015-02-15

    Highlights: • A presynthesized Ni-20Cr nanocrystalline powder was successfully deposited on T22 and SA 516 boilers steels using cold spray process. • The coatings are observed to have more than 2-folds microhardness in comparison with the base steels. • The coating was successful in reducing the weight gain of T22 and SA 516 steel by 71% and 94%. - Abstract: In the current investigation, high temperature oxidation behavior of a novel cold-spray Ni-20Cr nanostructured coating was studied. The nanocrystalline Ni-20Cr powder was synthesized by the investigators using ball milling, which was deposited on T22 and SA 516 steels by cold spraying. The crystallite size based upon Scherrer's formula for the developed coatings was found to be in nano-range for both the substrates. The accelerated oxidation testing was performed in a laboratory tube furnace at a temperature 900 °C under thermal cyclic conditions. Each cycle comprised heating for one hour at 900 °C followed by cooling for 20 min in ambient air. The kinetics of oxidation was established using weight change measurements for the bare and the coated steels. The oxidation products were characterized by X-ray Diffraction (XRD), Scanning Electron Microscopy/Energy Dispersive Spectroscopy (SEM/EDS) and X-ray mapping techniques. It was found from the results that the coating was successful in reducing the weight gain of SA213-T22 and SA 516-Grade 70 steel by 71% and 94%, respectively. This may be attributed to relatively denser structure, lower porosity and lower oxide content of the coating. Moreover, the developed nano-structured Ni-20Cr powder coating was found to perform better than its counterpart micron-sized Ni-20Cr powder coating, in terms of offering higher oxidation resistance and hardness.

  9. Study of mechanical properties and high temperature oxidation behavior of a novel cold-spray Ni-20Cr coating on boiler steels

    Science.gov (United States)

    Kaur, Narinder; Kumar, Manoj; Sharma, Sanjeev K.; Kim, Deuk Young; Kumar, S.; Chavan, N. M.; Joshi, S. V.; Singh, Narinder; Singh, Harpreet

    2015-02-01

    In the current investigation, high temperature oxidation behavior of a novel cold-spray Ni-20Cr nanostructured coating was studied. The nanocrystalline Ni-20Cr powder was synthesized by the investigators using ball milling, which was deposited on T22 and SA 516 steels by cold spraying. The crystallite size based upon Scherrer's formula for the developed coatings was found to be in nano-range for both the substrates. The accelerated oxidation testing was performed in a laboratory tube furnace at a temperature 900 °C under thermal cyclic conditions. Each cycle comprised heating for one hour at 900 °C followed by cooling for 20 min in ambient air. The kinetics of oxidation was established using weight change measurements for the bare and the coated steels. The oxidation products were characterized by X-ray Diffraction (XRD), Scanning Electron Microscopy/Energy Dispersive Spectroscopy (SEM/EDS) and X-ray mapping techniques. It was found from the results that the coating was successful in reducing the weight gain of SA213-T22 and SA 516-Grade 70 steel by 71% and 94%, respectively. This may be attributed to relatively denser structure, lower porosity and lower oxide content of the coating. Moreover, the developed nano-structured Ni-20Cr powder coating was found to perform better than its counterpart micron-sized Ni-20Cr powder coating, in terms of offering higher oxidation resistance and hardness.

  10. Parameter Studies on High-Velocity Oxy-Fuel Spraying of CoNiCrAlY Coatings Used in the Aeronautical Industry

    Directory of Open Access Journals (Sweden)

    J. A. Cabral-Miramontes

    2014-01-01

    Full Text Available The thermal spraying process is a surface treatment which does not adversely affect the base metal on which it is performed. The coatings obtained by HVOF thermal spray are employed in aeronautics, aerospace, and power generation industries. Alloys and coatings designed to resist oxidizing environments at high temperatures should be able to develop a surface oxide layer, which is thermodynamically stable, slowly growing, and adherent. MCrAlY type (M = Co, Ni or combination of both coatings are used in wear and corrosion applications but also provide protection against high temperature oxidation and corrosion attack in molten salts. In this investigation, CoNiCrAlY coatings were produced employing a HVOF DJH 2700 gun. The work presented here focuses on the influences of process parameters of a gas-drive HVOF system on the microstructure, adherence, wear, and oxygen content of CoNiCrAlY. The results showed that spray distance significantly affects the properties of CoNiCrAlY coatings.

  11. Thermally Sprayed Aluminum (TSA) Coatings for Extended Design Life of 22%Cr Duplex Stainless Steel in Marine Environments

    Science.gov (United States)

    Paul, S.; Shrestha, S.; Lee, C. M.; Harvey, M. D. F.

    2013-03-01

    In this article, evaluation of sealed and unsealed thermally sprayed aluminum (TSA) for the protection of 22%Cr duplex stainless steel (DSS) from corrosion in aerated, elevated temperature synthetic seawater is presented. The assessments involved general and pitting corrosion tests, external chloride stress corrosion cracking (SCC), and hydrogen-induced stress cracking (HISC). These tests indicated that DSS samples, which would otherwise fail on their own in a few days, did not show pitting or fail under chloride SCC and HISC conditions when coated with TSA (with or without a sealant). TSA-coated specimens failed only at very high stresses (>120% proof stress). In general, TSA offered protection to the underlying or exposed steel by cathodically polarizing it and forming a calcareous deposit in synthetic seawater. The morphology of the calcareous deposit was found to be temperature dependent and in general was of duplex nature. The free corrosion rate of TSA in synthetic seawater was measured to be ~5-8 μm/year at ~18 °C and ~6-7 μm/year at 80 °C.

  12. Evaluation of hot corrosion behaviour of HVOF sprayed Ni-5Al and NiCrAl coatings in coal fired boiler environment

    Energy Technology Data Exchange (ETDEWEB)

    Mahesh, R.A.; Jayaganthan, R.; Prakash, S. [VA Tech EWF Pvt Ltd., Prithla (India)

    2010-08-15

    Hot corrosion was recognised as a serious problem in connection with the degradation of fireside boiler tubes in coal fired steam generating plants. It is one of the most deleterious forms of surface degradation which can lead to the loss of mechanical strength and catastrophic failure of structural and engineering components. In the present investigation, an attempt has been made to evaluate the hot corrosion behaviour of high velocity oxyfuel (HVOF) sprayed Ni-5Al and NiCrAl coatings on iron based superalloy in an actual coal fired boiler environment. The coated specimens were hung in the low temperature superheater zone (about 700{sup o}C) of a coal fired boiler. The studies were carried out for 10 cycles each cycle consisting of exposing the coated specimens for 100 h followed by 1 h cooling to ambient conditions. NiCrAl coated specimen provided better resistance to hot corrosion than Ni-5Al coated specimen in the given environment.

  13. The Influence of Temperature on Frictional Behavior of Plasma-Sprayed NiAl-Cr2O3 Based Self-Adaptive Nanocomposite Coatings

    Science.gov (United States)

    Ramazani, M.; Ashrafizadeh, F.; Mozaffarinia, R.

    2013-10-01

    Frictional behavior of nano and hybrid-structured NiAl-Cr2O3-Ag-CNT-WS2 adaptive self-lubricant coatings was evaluated at a range of temperatures, from room temperature to 700 °C. For this purpose, hybrid structured (HS) and nanostructured (NS) composite powders with the same nominal compositions were prepared by spray drying and heat treatment techniques. A series of HS and NS coating samples were deposited on steel substrate by an atmospheric plasma spraying process. The tribological behavior of both coatings was studied from room temperature to 700 °C at 100° intervals using a custom designed high temperature wear test machine. Scanning electron microscopy was employed for the evaluation of the composite coatings and worn surfaces. Experimental results indicated that the hybrid coating had inferior tribological properties when compared to the nanostructured coating, showing the attractive frictional behavior on the basis of low friction and high wear resistance; the NS coating possessed a more stable friction coefficient in the temperature range of 25-700 °C against alumina counterface. Microstructural examinations revealed more uniformity in NS plasma-sprayed coatings.

  14. Microstructure and Wear Behavior of FeCoCrNiMo0.2 High Entropy Coatings Prepared by Air Plasma Spray and the High Velocity Oxy-Fuel Spray Processes

    Directory of Open Access Journals (Sweden)

    Tianchen Li

    2017-09-01

    Full Text Available In the present research, the spherical FeCoCrNiMo0.2 high entropy alloy (HEA powders with a single FCC solid solution structure were prepared by gas atomization. Subsequently, the FeCoCrNiMo0.2 coatings with a different content of oxide inclusions were prepared by air plasma spraying (APS and high-velocity oxy-fuel spraying (HVOF, respectively. The microstructure, phase composition, mechanical properties, and tribological behaviors of these HEA coatings were investigated. The results showed that both HEA coatings showed a typical lamellar structure with low porosity. Besides the primary FCC phase, a mixture of Fe2O3, Fe3O4, and AB2O4 (A = Fe, Co, Ni, and B = Fe, Cr was identified as the oxide inclusions. The oxide content of the APS coating and HVOF coating was calculated to be 47.0% and 12.7%, respectively. The wear resistance of the APS coating was approximately one order of magnitude higher than that of the HVOF coating. It was mainly attributed to the self-lubricated effect caused by the oxide films. The mass loss of the APS coating was mainly ascribed to the breakaway of the oxide film, while the main wear mechanism of the HVOF coating was the abrasive wear.

  15. Plasma sprayed coatings on crankshaft used steels

    Science.gov (United States)

    Mahu, G.; Munteanu, C.; Istrate, B.; Benchea, M.

    2017-08-01

    Plasma spray coatings may be an alternative to conventional heat treatment of main journals and crankpins of the crankshaft. The applications of plasma coatings are various and present multiple advantages compared to electric arc wire spraying or flame spraying. The study examines the layers sprayed with the following powders: Cr3C2- 25(Ni 20Cr), Al2O3- 13TiO2, Cr2O3-SiO2- TiO2 on the surface of steels used in the construction of a crankshaft (C45). The plasma spray coatings were made with the Spray wizard 9MCE facility at atmospheric pressure. The samples were analyzed in terms of micro and morphological using optical microscopy, scanning electron microscopy and X-ray diffraction. Wear tests on samples that have undergone simulates extreme working conditions of the crankshafts. In order to emphasize adherence to the base material sprayed layer, were carried out tests of microscratches and micro-indentation. Results have showed a relatively compact morphological aspect given by the successive coatings with splat-like specific structures. Following the microscratch analysis it can be concluded that Al2O3-13TiO2 coating has a higher purpose in terms of hardness compared to Cr3C2-(Ni 20Cr) and Cr2O3-SiO2- TiO2 powders. Thermal coatings of the deposited powders have increased the mechanical properties of the material. The results stand to confirm that plasma sprayed Al2O3-13TiO2 powder is in fact a efficient solution for preventing mechanical wear, even with a faulty lubrication system.

  16. Investigations on the Behavior of HVOF and Cold Sprayed Ni-20Cr Coating on T22 Boiler Steel in Actual Boiler Environment

    Science.gov (United States)

    Bala, Niraj; Singh, Harpreet; Prakash, Satya; Karthikeyan, J.

    2012-01-01

    High temperature corrosion accompanied by erosion is a severe problem, which may result in premature failure of the boiler tubes. One countermeasure to overcome this problem is the use of thermal spray protective coatings. In the current investigation high velocity oxy-fuel (HVOF) and cold spray processes have been used to deposit commercial Ni-20Cr powder on T22 boiler steel. To evaluate the performance of the coatings in actual conditions the bare as well as the coated steels were subjected to cyclic exposures, in the superheater zone of a coal fired boiler for 15 cycles. The weight change and thickness loss data were used to establish kinetics of the erosion-corrosion. X-ray diffraction, surface and cross-sectional field emission scanning electron microscope/energy dispersive spectroscopy (FE-SEM/EDS) and x-ray mapping techniques were used to analyse the as-sprayed and corroded specimens. The HVOF sprayed coating performed better than its cold sprayed counterpart in actual boiler environment.

  17. Optimization of the Arc Spraying Process Parameters of the Fe–Base Mn-Si-Cr-Mo-Ni Coatings for the Best Wear Performance

    Directory of Open Access Journals (Sweden)

    Justinas GARGASAS

    2016-05-01

    Full Text Available In this paper, the use of Fe–base Mn-Si-Cr-Mo-Ni and Fe–base Mn-Si-Cr wires for thermal arc spraying is presented. For this purpose the mechanical and physical properties of coatings were evaluated. The quality of the coating’s was dependent on the selected equipment, spray materials, technological parameters of the spray and spray technology. The aim was to qualify and optimize the parameters for spray coating to get the best coatings properties with good tribological properties. All coatings were deposited on mild steel S235JR substrates. Two experimental cored wires of unique chemical composition – STEIN-MESYFIL 932 V and STEIN-MESYFIL 954 V – were used for thermal arc spraying. The wires of 1.6 mm diameter were used for the surfacing material. Hardness, porosity and oxide measurements were used to verify the spray parameters and analyze the coatings. Rubber wheel test, which is based on the standard ASTM G65, was used. Dry-sand, rubber-wheel procedure according ASTM G65 was used to investigate low stress abrasion, whereas for high stress abrasion investigations a rubber wheel was used. This experiment was carried out by changing the speed of disc friction, travel distance and measuring the mass loss of surface friction. Miller Test according to ASTM G75-95 Standard was carried out in experiment with friction. The samples were immersed in water with corundum and polished with 22 N load, for 8 hours. Furthermore a correlation was performed between the spraying current and voltage parameter. The coatings’ cross sections were examined using scanning electron microscope (SEM and optical microscopy. The influence of the composite components of the coatings’ microstructure, such as porosity, microhardness, oxide inclusions, on the tribological properties of thermal sprayed coatings is discussed in this paper. DOI: http://dx.doi.org/10.5755/j01.ms.22.1.7339

  18. Optimization of the Arc Spraying Process Parameters of the Fe–Base Mn-Si-Cr-Mo-Ni Coatings for the Best Wear Performance

    Directory of Open Access Journals (Sweden)

    Justinas GARGASAS

    2016-05-01

    Full Text Available In this paper, the use of Fe–base Mn-Si-Cr-Mo-Ni and Fe–base Mn-Si-Cr wires for thermal arc spraying is presented. For this purpose the mechanical and physical properties of coatings were evaluated. The quality of the coating’s was dependent on the selected equipment, spray materials, technological parameters of the spray and spray technology. The aim was to qualify and optimize the parameters for spray coating to get the best coatings properties with good tribological properties. All coatings were deposited on mild steel S235JR substrates. Two experimental cored wires of unique chemical composition – STEIN-MESYFIL 932 V and STEIN-MESYFIL 954 V – were used for thermal arc spraying. The wires of 1.6 mm diameter were used for the surfacing material. Hardness, porosity and oxide measurements were used to verify the spray parameters and analyze the coatings. Rubber wheel test, which is based on the standard ASTM G65, was used. Dry-sand, rubber-wheel procedure according ASTM G65 was used to investigate low stress abrasion, whereas for high stress abrasion investigations a rubber wheel was used. This experiment was carried out by changing the speed of disc friction, travel distance and measuring the mass loss of surface friction. Miller Test according to ASTM G75-95 Standard was carried out in experiment with friction. The samples were immersed in water with corundum and polished with 22 N load, for 8 hours. Furthermore a correlation was performed between the spraying current and voltage parameter. The coatings’ cross sections were examined using scanning electron microscope (SEM and optical microscopy. The influence of the composite components of the coatings’ microstructure, such as porosity, microhardness, oxide inclusions, on the tribological properties of thermal sprayed coatings is discussed in this paper. DOI: http://dx.doi.org/10.5755/j01.ms.22.1.7339

  19. Slurry Erosion Performance Study of Detonation Gun-Sprayed WC-10Co-4Cr Coatings on CF8M Steel Under Hydro-Accelerated Conditions

    Science.gov (United States)

    Bhandari, Sanjeev; Singh, Harpreet; Kumar, Harmesh; Rastogi, Vikas

    2012-09-01

    In the current investigation, cermet coatings (WC-10Co-4Cr) were deposited on CF8M steel by detonation gun (D-gun) thermal spraying process. Subsequently, the slurry erosion behaviors of the coated and bare steels were investigated using a high-speed erosion test rig. Slurry collected from an actual hydro power plant was used as the abrasive media. Effects of concentration (ppm), average particle sizes and rotational speed on the slurry erosion behaviors of coated and bare steels under different experimental conditions were studied. The analysis of eroded samples was done using SEM and stylus profilometry. Signatures of microcutting, fracture of well-bonded WC grains, and fragmentations were observed on the eroded surface of WC-10Co-4Cr coating, while signatures of formation of plowing, lips, shearing of platelet, formation of crater, and micro-cutting were observed on the eroded surface of CF8M steel.

  20. Slurry Erosion Behavior of F6NM Stainless Steel and High-Velocity Oxygen Fuel-Sprayed WC-10Co-4Cr Coating

    Science.gov (United States)

    Cui, S. Y.; Miao, Q.; Liang, W. P.; Huang, B. Z.; Ding, Z.; Chen, B. W.

    2017-02-01

    WC-10Co-4Cr coating was applied to the surface of F6NM stainless steel by high-velocity oxygen-fuel spraying. The slurry erosion behavior of the matrix and coating was examined at different rotational speeds using a self-made machine. This experiment effectively simulates real slurry erosion in an environment with high silt load. At low velocity (<6 m/s), the main failure mechanism was cavitation. Small bubbles acted as an air cushion, obstructing direct contact between sand and the matrix surface. However, at velocity above 9 m/s, abrasive wear was the dominant failure mechanism. The results indicate that WC-10Co-4Cr coating significantly improved the slurry resistance at higher velocity, because it created a thin and dense WC coating on the surface.

  1. 碳钢表面等离子喷涂Cr2O3涂层及其耐腐蚀性能%Corrosion Resistance of Plasma Sprayed Cr2O3 Coating on Carbon Steel

    Institute of Scientific and Technical Information of China (English)

    糜亮; 李水清; 丁毅; 马立群

    2011-01-01

    Cr2O3 coating on carbon steel was prepared by plasma spraying. The micro-structure and corrosion resistance of the spayed coating were characterized by scanning electron microscopy (SEM), X-ray diffraction (XRD) and electrochemical tests. The results showed that the thickness of the coating was about 100μm and the phase composition was mainly Cr2O3. The corrosion rate of the Cr2O3 coating decreased dramaticlly after spraying Cr2O3.%利用等离子喷涂技术在45(XRD)等方法表征了涂层的微观形貌、表面元素组成以及相结构;测量了涂层的显微硬度;采用CS300P型电化学工作站检测了Cr2O3涂层的耐蚀性能.结果表明,在45#钢表面等离子喷涂CrzO3涂层的厚度约为100μm,相成分主要是Cr2O3;显微硬度值达到莫氏9级;喷涂Cr3Oa涂层后的试样腐蚀速率显著降低,耐蚀性能明显提高.

  2. Microstructure studies of air-plasma-spray-deposited CoNiCrAlY coatings before and after thermal cyclic loading for high-temperature application

    Institute of Scientific and Technical Information of China (English)

    Dipak Kumar; KN Pandey; Dipak Kumar Das

    2016-01-01

    In the present study, bond-coats for thermal barrier coatings were deposited via air plasma spraying (APS) techniques onto Inconel 800 and Hastelloy C-276 alloy substrates. Scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), and atomic force microscopy (AFM) were used to investigate the phases and microstructure of the as-sprayed, APS-deposited CoNiCrAlY bond-coatings. The aim of this work was to study the suitability of the bond-coat materials for high temperature applications. Confirmation of nanoscale grains of theγ/γ′-phase was obtained by TEM, high-resolution TEM, and AFM. We concluded that these changes result from the plastic deformation of the bond-coat during the deposition, resulting in CoNiCrAlY bond-coatings with excellent thermal cy-clic resistance suitable for use in high-temperature applications. Cyclic oxidative stability was observed to also depend on the underlying metallic alloy substrate.

  3. Microstructure studies of air-plasma-spray-deposited CoNiCrAlY coatings before and after thermal cyclic loading for high-temperature application

    Science.gov (United States)

    Kumar, Dipak; Pandey, K. N.; Das, Dipak Kumar

    2016-08-01

    In the present study, bond-coats for thermal barrier coatings were deposited via air plasma spraying (APS) techniques onto Inconel 800 and Hastelloy C-276 alloy substrates. Scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), and atomic force microscopy (AFM) were used to investigate the phases and microstructure of the as-sprayed, APS-deposited CoNiCrAlY bond-coatings. The aim of this work was to study the suitability of the bond-coat materials for high temperature applications. Confirmation of nanoscale grains of the γ/γ'-phase was obtained by TEM, high-resolution TEM, and AFM. We concluded that these changes result from the plastic deformation of the bond-coat during the deposition, resulting in CoNiCrAlY bond-coatings with excellent thermal cyclic resistance suitable for use in high-temperature applications. Cyclic oxidative stability was observed to also depend on the underlying metallic alloy substrate.

  4. High temperature oxidation studies of detonation-gun-sprayed Cr{sub 3}C{sub 2}-NiCr coating on Fe- and Ni-based superalloys in air under cyclic condition at 900 deg. C

    Energy Technology Data Exchange (ETDEWEB)

    Kamal, Subhash [Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, IIT Roorkee Campus, Roorkee 247667, Uttaranchal (India); Jayaganthan, R. [Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, IIT Roorkee Campus, Roorkee 247667, Uttaranchal (India)], E-mail: rjayafmt@iitr.ernet.in; Prakash, S. [Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, IIT Roorkee Campus, Roorkee 247667, Uttaranchal (India)

    2009-03-20

    The cyclic oxidation behavior of detonation-gun-sprayed Cr{sub 3}C{sub 2}-NiCr coating on three different superalloys namely Superni 75, Superni 718 and Superfer 800H at 900 deg. C for 100 cycles in air under cyclic heating and cooling conditions has been investigated in the present work. The kinetics of oxidation of coated and bare superalloys was analysed, using thermogravimetric technique. It was observed that all the coated and bare superalloys obey a parabolic rate law of oxidation. X-ray diffraction, FE-SEM/EDAX and X-ray mapping techniques were used to analyse the oxidation products of coated and bare superalloys. The results on the Cr{sub 3}C{sub 2}-NiCr-coated superalloys showed better oxidation resistance due to the formation of a compact and adhesive thin Cr{sub 2}O{sub 3} scale on the surface of the coating during oxidation. The scale remained intact and adherent to the partially oxidised coating during cyclic oxidation due to its good compatibility and similar thermal expansion coefficient between Cr{sub 3}C{sub 2}-NiCr coating and the superalloy substrates. In all the coated superalloys, the chromium, iron, silicon and titanium were oxidised in the inter-splat region, whereas splats which consisted mainly of Ni remained unoxidised. The parabolic rate constants of Cr{sub 3}C{sub 2}-NiCr-coated alloys were lower than that of the bare superalloys as observed in the present work.

  5. Effects of La2O3 on the microstructure and tribological properties of plasma-sprayed Cr2O3-TiO2 coatings

    Science.gov (United States)

    Ding, Qingjun; Zhang, Aihua; Zhao, Gai; Peng, Hanmin; Gao, Wei

    2017-07-01

    Cr2O3-TiO2 coatings with different proportions of La2O3 were deposited by atmospheric plasma spraying. The coatings were evaluated by hardness tester, surface roughness tester, SEM and wear tester. The experiment results showed that the addition of La2O3 could improve the microhardness and decrease porosity, wear rate and surface roughness of the coating. The coating containing 2 wt.% La2O3 had the best tribological properties. The dominant wear mechanism is a mixture of abrasive wear and adhesive wear. The microscopic analysis suggests that the addition of La2O3 could refine the microstructure and promote the formation of solid solution powder, and then affect the properties of coatings.

  6. Effect of Spray Particle Velocity on Cavitation Erosion Resistance Characteristics of HVOF and HVAF Processed 86WC-10Co4Cr Hydro Turbine Coatings

    Science.gov (United States)

    Kumar, R. K.; Kamaraj, M.; Seetharamu, S.; Pramod, T.; Sampathkumaran, P.

    2016-08-01

    The hydro plants utilizing silt-laden water for power generation suffer from severe metal wastage due to particle-induced erosion and cavitation. High-velocity oxy-fuel process (HVOF)-based coatings is widely applied to improve the erosion life. The process parameters such as particle velocity, size, powder feed rate, temperature, affect their mechanical properties. The high-velocity air fuel (HVAF) technology, with higher particle velocities and lower spray temperatures, gives dense and substantially nonoxidized coating. In the present study, the cavitation resistance of 86WC-10Co4Cr-type HVOF coating processed at 680 m/s spray particle velocity was compared with HVAF coatings made at 895, 960, and 1010 m/s. The properties such as porosity, hardness, indentation toughness, and cavitation resistance were investigated. The surface damage morphology has been analyzed in SEM. The cohesion between different layers has been examined qualitatively through scratch depth measurements across the cross section. The HVAF coatings have shown a lower porosity, higher hardness, and superior cavitation resistance. Delamination, extensive cracking of the matrix interface, and detachment of the WC grains were observed in HVOF coating. The rate of metal loss is low in HVAF coatings implying that process parameters play a vital role in achieving improved cavitation resistance.

  7. Mechanical property changes in HVOF sprayed nano-structured WC-17wt.%Ni(80/20)Cr coating with varying substrate roughness

    Science.gov (United States)

    Ben Mahmud, Tarek A.; Saha, Gobinda C.; Khan, Tahir I.

    2014-06-01

    Thermally sprayed coatings developed by use of high velocity oxy-fuel (HVOF) process are known for their superior wear characteristics. In many industrial applications, new parts as well as repaired and refurbished parts coated with WC-Co microstructured coatings have shown enhanced erosion-corrosion and abrasive resistant properties when compared with other surface modification technologies such as chrome replacement, fusion welding, and cladding. This research has been further directed towards the development of HVOF technique to deposit dense nanostructured ceramic-metallic composites. The mechanism of plastic deformation, which determines the strength and ductility of materials, in nanostructured materials are different, thereby leading to novel mechanical properties. Various parameters can influence these properties, but the substrate surface preparation by grit blasting before thermal spraying is one critical parameter. The grit blasting process generates a surface roughness, which ensures mechanical anchoring between the coating and the substrate surface. In this work, the sliding wear behavior and microhardness of WC-17wt.%Ni(80/20)Cr cermet coatings deposited onto carbon steel substrates are examined as a function of three different surface roughness values under different loads. The results show that as-prepared surface with different blasting profiles have a direct influence on the surface roughness and wear performance of the coatings. The sliding wear resistance of the coatings increased as the substrate surface roughness increased. The wear depth decreased with increasing surface roughness.

  8. Erosion behaviour of WC-10Co-4Cr coating on 23-8-N nitronic steel by HVOF thermal spraying

    Science.gov (United States)

    kumar, Avnish; Sharma, Ashok; Goel, S. K.

    2016-05-01

    WC-10Co-4Cr coating was deposited by high-velocity oxy-fuel (HVOF) process on cast and solution treated (1220 °C/150 min) 23-8-N nitronic steel substrates. Solution treated substrate has shown higher toughness, ductility and impact energy with a marginal reduction in hardness as compared to cast substrate. This influence the coating deposition efficiency and erosion behaviour. Erosion resistance of coatings was evaluated by air jet erosion tester on two different impact angles (30° and 90°). Phases, microstructure and eroded surface of the coating were characterised by X-ray diffraction (XRD) analysis and field-emission scanning electron microscopy (FESEM) respectively. It is observed that coating on solution treated substrate was superior to cast substrate. The reason being that coating has dense and well-bonded structure with low porosity, less decarburization and inter-splat oxidation. Higher erosion resistance of coated solution treated 23-8-N nitronic steel was attributed to combination of high fracture toughness and hardness of coating including optimum mechanical properties of the substrate. FESEM analysis reveals that erosion response of WC-10Co-4Cr coating also dependent on the relative size of the impact crater with respect to the WC grain size. Coating is removed by combined mode of ductile and brittle erosion.

  9. Hot Corrosion Studies of Detonation-Gun-Sprayed NiCrAlY + 0.4 wt.% CeO2 Coated Superalloys in Molten Salt Environment

    Science.gov (United States)

    Kamal, Subhash; Jayaganthan, R.; Prakash, Satya

    2011-08-01

    Rare earth oxide (CeO2) has been incorporated in NiCrAlY alloy and hot corrosion resistance of detonation-gun-sprayed NiCrAlY + 0.4 wt.% CeO2 coatings on superalloys, namely, superni 75, superni 718, and superfer 800H in molten 40% Na2SO4-60% V2O5 salt environment were investigated at 900 °C for 100 cycles. The coatings exhibited characteristic splat globular dendritic structure with diameter similar to the original powder particles. The weight change technique was used to establish corrosion kinetics. X-ray diffraction (XRD), field emission scanning electron microscopy/energy-dispersive analysis (FE-SEM/EDAX), and x-ray mapping techniques were used to analyze the corrosion products. Coated superfer 800H alloy showed the highest corrosion resistance among the examined superalloys. CeO2 was found to be distributed in the coating along the splat boundaries, whereas Al streaks distributed non-uniformly. The main phases observed for the coated superalloys are oxides of Ni, Cr, Al, and spinels, which are suggested to be responsible for developing corrosion resistance.

  10. High temperature corrosion of thermally sprayed NiCr- and amorphous Fe-based coatings covered with a KCl-K{sub 2}SO{sub 4} salt

    Energy Technology Data Exchange (ETDEWEB)

    Varis, T.; Suhonen, T.; Tuurna, S.; Ruusuvuori, K.; Holmstroem, S.; Salonen, J. [VTT, Espoo (Finland); Bankiewicz, D.; Yrjas, P. [Aabo Akademi Univ., Turku (Finland)

    2010-07-01

    New process conditions due to the requirement of higher efficiency together with the use of high-chlorine and alkali containing fuels such as biomass and waste fuels for heat and electricity production will challenge the resistance and life of tube materials. In conventional materials the addition of alloying elements to increase the corrosion resistance in aggressive combustion conditions increases costs relatively rapidly. Thermally sprayed coating offer promising, effective, flexible and cost efficient solutions to fulfill the material needs for the future. Some heat exchanger design alteractions before global commercialization have to be overcome, though. High temperature corrosion in combustion plants can occur by a variety of mechanisms including passive scale degradation with subsequent rapid scaling, loss of adhesion and scale detachment, attack by melted or partly melted deposits via fluxing reactions and intergranular-/interlamellar corrosion. A generally accepted model of the ''active oxidation'' attributes the responsibility for inducing corrosion to chlorine. The active oxidation mechanism plays a key role in the thermally sprayed coatings due to their unique lamellar structure. In this study, the corrosion behaviour of NiCr (HVOF and Wire Arc), amorphous Fe-based, and Fe13Cr (Wire Arc) thermally sprayed coatings, were tested in the laboratory under simplified biomass combustion conditions. The tests were carried out by using a KCl-K{sub 2}SO{sub 4} salt mixture as a synthetic biomass ash, which was placed on the materials and then heat treated for one week (168h) at two different temperatures (550{sup 0}C and 600 C) and in two different gas atmospheres (air and air+30%H{sub 2}O). After the exposures, the metallographic cross sections of the coatings were studied with SEM/EDX analyzer. The results showed that the coatings behaved relatively well at the lower test temperature while critical corrosion through the lamella boundaries

  11. Thermal Expansion of Vacuum Plasma Sprayed Coatings

    Science.gov (United States)

    Raj, S V.; Palczer, A. R.

    2010-01-01

    Metallic Cu-8%Cr, Cu-26%Cr, Cu-8%Cr-1%Al, NiAl and NiCrAlY monolithic coatings were fabricated by vacuum plasma spray deposition processes for thermal expansion property measurements between 293 and 1223 K. The corrected thermal expansion, (DL/L(sub 0) varies with the absolute temperature, T, as (DL/L(sub 0) = A(T - 293)(sup 3) + BIT - 293)(sup 2) + C(T - 293) + D, where, A, B, C and D are thermal, regression constants. Excellent reproducibility was observed for all of the coatings except for data obtained on the Cu-8%Cr and Cu-26%Cr coatings in the first heat-up cycle, which deviated from those determined in the subsequent cycles. This deviation is attributed to the presence of residual stresses developed during the spraying of the coatings, which are relieved after the first heat-up cycle. In the cases of Cu-8%Cr and NiAl, the thermal expansion data were observed to be reproducible for three specimens. The linear expansion data for Cu-8% Cr and Cu-26%Cr agree extremely well with rule of mixture (ROM) predictions. Comparison of the data for the Cu-8%Cr coating with literature data for Cr and Cu revealed that the thermal expansion behavior of this alloy is determined by the Cu-rich matrix. The data for NiAl and NiCrAlY are in excellent agreement with published results irrespective of composition and the methods used for processing the materials. The implications of these results on coating GRCop-84 copper alloy combustor liners for reusable launch vehicles are discussed.

  12. Microplasma sprayed hydroxyapatite coatings

    CERN Document Server

    Dey, Arjun

    2015-01-01

    ""This unique book on development of microplasma sprayed HAp coating has been organized in a very compact yet comprehensive manner. This book also highlights the horizons of future research that invites the attention of global community, particularly those in bio-medical materials and bio-medical engineering field. This book will surely act as a very useful reference material for both graduate/post-graduate students and researchers in the field of biomedical, orthopedic and manufacturing engineering and research. I truly believ that this is the first ever effort which covers almost all the

  13. 用烧结型粉末喷涂的镍铬-碳化铬耐磨涂层%Atmospheric Plasma Sprayed Cr3C2-NiCr Wear Resistant Coating

    Institute of Scientific and Technical Information of China (English)

    肇国锋; 张佳平; 岳阳; 王璐; 袁福河

    2012-01-01

    Chromium carbide nickel-chrome cermet coating is one of the most applied wear resistant coatings operating at high temperatures for aero-engine. The present work addresses the chromium carbide nickel-chrome coating prepared by an optimized air plasma spraying process with a sintered Cr3C2-30%NiCr powder. The coating possesses a uniform microstructure and the oxides are evenly distributed with accompanying small porosities and un-melted particles. The Cr3C2-30% NiCr coating has minimum tensile bond strength of 40 MPa which is significantly higher than that of the coating sprayed with Metco 81 VF-NS powder. However, the superficial Rockwell hardness and blast grit erosion resistance of the above two coatings are similar. The developed spray processes have been applied to plasma spray production of a front-bearing casing for an aero-engine due to its satisfaction of all en~neerin~ renllirementg%镍铬-碳化铬涂层是航空发动机常用的高温耐磨涂层之一。本研究通过优化大气等离子喷涂工艺,用烧结型粉末制备了镍铬-碳化铬涂层。涂层显微组织均匀,氧化物弥散分布、孔洞及未熔颗粒较小。Cr3C2-30%NiCr涂层的拉伸结合强度不小于40MPa,显著高于Metco81VF—Ns粉末喷涂的涂层,用两种粉末喷涂涂层的表面洛氏硬度及耐砂粒冲蚀性能相近。Cr3C2-30%NiCr涂层性能符合设计要求,喷涂工艺现已被用于某型号发动机的前轴承机匣零部件的喷涂生产。

  14. The Characterization of Twin-Wire Arc-Sprayed FeCrBSi Coating and the Application in Sewage Sludge Boilers

    Science.gov (United States)

    Qin, Enwei; Huang, Qian; Shao, Yumin; Chen, Guoxing; Ye, Lin; Gu, Qin; Wu, Shuhui

    2014-12-01

    Incineration in boilers is an environment-friendly treatment for industrial and civil sewage sludge. However, due to the aggressive nature of the sludge, the boiler fireside-surface is subjected to severe wear, erosive, and high temperature corrosion problems during incineration. In this study, we developed an economical FeCrBSi wire material with iron weight content as high as 80%. The coating was prepared by twin-wire arc spraying processing. The chemical compositions of the coating, as well as phase components were analyzed by energy-dispersive spectroscopy and x-ray diffraction method. The surface roughness, porosity, and cross-sectional morphology were further characterized. The coating hardness is close to that of the commercial Armacor M and Armacor C materials. In-boiler test was also carried out. The low thickness loss of the tube indicates a promising application future in sludge boilers.

  15. hBN含量对等离子喷涂NiCr/Cr3C2-hBN复合涂层力学性能的影响%Effect of hBN content on mechanical properties of plasma-sprayed NiCr/Cr3 C2-hBN composite coating

    Institute of Scientific and Technical Information of China (English)

    曹玉霞; 杜令忠; 张伟刚; 兰叶; 黄传兵

    2015-01-01

    Taking hBN and Cr3 C2 as core, NiCr/Cr3 C2-hBN composite powder were prepared with the technologies of spray granulation, chemical and metallurgical coating and solid state alloying. The NiCr/Cr3 C2-hBN composite coating was prepared by plasma-spray technology. Microstructure, phase composition, microhardness and tensile strength of the coating were investigated. The results show that the NiCr/Cr3 C2-hBN composite coating consisted of typical lamellae and exhibited excellent binding strength. Both the microhardness and binding strength of the coating decrease with the increase of hBN content. When the hBN content is 20%, microhardness and tensile strength of the coating are 66% and 50% of these of the NiCr/Cr3 C2 coating, respectively. The peeling occurs inside coating and is typical brittle fracture.%采用化工冶金包覆、喷雾造粒和固相合金化技术以Cr3 C2和hBN为核心制备了NiCr/Cr3 C2-hBN复合粉体,并用等离子喷涂技术制备了NiCr/Cr3 C2-hBN涂层,研究了涂层的显微结构、物相组成、显微硬度和结合强度。研究结果表明,等离子喷涂NiCr/Cr3 C2-hBN复合涂层呈典型的层状结构,各层之间结合良好。涂层的显微硬度和结合强度均随hBN含量的增加逐渐降低,当hBN含量为20%时,涂层的显微硬度和结合强度分别为NiCr/Cr3 C2涂层的66%和50%。涂层断裂位置发生在涂层内部,为典型的脆性断裂。

  16. Evaluation of hot corrosion behaviour of HVOF sprayed NiCrAl coating on superalloys at 900 deg. C

    Energy Technology Data Exchange (ETDEWEB)

    Mahesh, R.A. [Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, IIT Roorkee Campus, Roorkee 247667, Uttarakhand (India); Jayaganthan, R. [Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, IIT Roorkee Campus, Roorkee 247667, Uttarakhand (India)], E-mail: rjayafmt@iitr.ernet.in; Prakash, S. [Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, IIT Roorkee Campus, Roorkee 247667, Uttarakhand (India)

    2008-10-15

    In the present investigation, NiCrAl coating was deposited on Ni- and Fe-based superalloy substrates by using high velocity oxy-fuel (HVOF) process to study the hot corrosion behaviour in molten salt (Na{sub 2}SO{sub 4}-60% V{sub 2}O{sub 5}) environment at 900 deg. C under cyclic conditions. The mass gain measurements were performed after each cycle to establish the kinetics of corrosion using thermogravimetric technique. X-ray diffraction (XRD), scanning electron microscopy/energy dispersive spectroscopic analysis (SEM/EDS) and X-ray mapping techniques were used to analyse the corrosion products. The bare superalloys experienced higher weight gain. The NiCrAl-coated Superni 750 alloy (SN 750) provided a better protection among the coated superalloys investigated. The formation of oxides and spinels of nickel, chromium and aluminum may be contributing better resistance to hot corrosion.

  17. Cold Spray Coating Technique with FeCrAl Alloy Powder for Developing Accident Tolerant Fuel Cladding

    Energy Technology Data Exchange (ETDEWEB)

    Park, Dong Jun; Kim, Hyun Gil; Park, Jeong Yong; Jung, Yang Il; Park, Jung Hwan; Koo, Yang Hyun [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2015-05-15

    Various approaches to enhance safety have been suggested, replacing current Zr-based alloys for fuel cladding with advanced materials exhibiting lower oxidation rates can be a basic solution. Many advanced materials such as FeCrAl alloys; Mn+1AXn, (MAX) phases, where n = 1 to 3, M is an early transition metal, A is an A-group (mostly IIIA and IVA, or groups 13 and 14) element and X is either carbon or nitrogen; Mo; and SiC are being considered as possible candidates. Among the proposed fuel cladding substitutes, Fe-based alloys are one of the most promising candidates owing to their excellent formability, high strength, and oxidation resistance at high temperature. In this work, the ATF technology concept of Fe-based alloy coating on the existing Zr-alloy cladding was considered and results on the optimization study for fabrication of coated tube samples were described. Result obtained from high temperature oxidation test under steam environment at 1200 .deg. C indicates that FeCrAl alloy coated Zr metal matrix may maintain its integrity during LOCA. This means that accident tolerance of FeCrAl alloy coated Zr cladding sample had been greatly improved compared to that of existing Zr-based alloy fuel cladding.

  18. Progress of Thermal Sprayed NiCrBSi Based Wear-resistant Coatings%热喷涂NiCrBSi基耐磨涂层的研究进展

    Institute of Scientific and Technical Information of China (English)

    徐海峰; 肖金坤; 张嘎; 张超

    2016-01-01

    Wear failure is one of the most common consumption patterns during industrial production and material life. Using thermal spray technology to improve friction and wear properties of friction pair surface has attracted increasing attention. As an im-portant surface technology, thermal spray has good application in the area of corrosion, wear, etc. NiCrBSi is a kind of Ni-based self-fluxing alloy in which Ni and Cr are main components. In recent years, researches on NiCrBSi based coatings have made im-portant progress in preparation, characterization and application. The first part of this article gave a detailed investigation of state of the art of Ni-based alloys, mainly discussed the research status on pure NiCrBSi coatings, self-lubricating properties of NiCrBSi-Mo coatings, hard phase enhancement of NiCrBSi-carbide coatings, comprehensive performances of NiCrBSi-oxide coatings. The sec-ond part presented the principles, characteristics and applications of flame, laser, furnace, inducting remelted NiCrBSi coatings. In this part, the effect of post-treatment on coating microstructure and wear performance was also taken into account. Meanwhile the effects of adding component and remelting processes on coating structure, mechanical properties and wear resistance performance were compared in order to clarify the wear mechanism. Finally, the main problems existing in NiCrBSi based wear-resistant coa-tings were summarized. Three suggestions from the viewpoints of materials, process and post-treatment were prospected.%磨损失效是工业生产及材料使用寿命最主要的消耗方式之一,通过热喷涂表面涂层技术提高摩擦副表面摩擦磨损性能受到越来越多的关注。作为一种重要的表面处理技术,热喷涂在防腐、耐磨等方面均有出色的表现。 NiCrBSi是以Ni、Cr为主要组元的Ni基自熔性合金,近年来,NiCrBSi基涂层在制备方法、性能表征和应用推广等方面都取得了重要进展。本文主

  19. A comparative study of high-temperature erosion wear of plasma-sprayed NiCrBSiFe and WC-NiCrBSiFe coatings under simulated coal-fired boiler conditions

    Energy Technology Data Exchange (ETDEWEB)

    Hidalgo, V.H.; Varela, F.J.B.; Menendez, A.C.; Martinez, S.P. [University of Oviedo, Gijon (Spain). Dept of Energy

    2001-03-01

    A comparative study was carried out of the behaviour of plasma sprayed NiCrBSiFe and WC-NiCrBSiFe alloys subjected to conditions which simulate a post-combustion gas atmosphere from a coal-fired boiler combustor. The study first evaluates the effects of thermal exposure at high temperatures on the microstructure of the coatings and on the adherence between substrate (austenitic stainless steel) and coatings. The oxidation rates of these coatings in atmospheres with 3-3.5% of free oxygen at 773 and 1073 K were then evaluated. The effect of WC on the low-velocity corrosion-erosion behaviour produced by the impact of fly ashes in the gas stream at high temperatures (773 and 1073 K) was assessed under impact angles of 30 and 90{degree}C. Finally, the eroded surfaces were analysed using scanning electron microscopy in order to characterize the ash embedment phenomena and the operating erosive micromechanisms.

  20. Desirability-Based Multi-Criteria Optimization of HVOF Spray Experiments to Manufacture Fine Structured Wear-Resistant 75Cr3C2-25(NiCr20) Coatings

    Science.gov (United States)

    Tillmann, W.; Vogli, E.; Baumann, I.; Kopp, G.; Weihs, C.

    2010-01-01

    Thermal spraying of fine feedstock powders allow the deposition of cermet coatings with significantly improved characteristics and is currently of great interest in science and industry. However, due to the high surface to volume ratio and the low specific weight, fine particles are not only difficult to spray but also show a poor flowability in the feeding process. In order to process fine powders reliably and to preserve the fine structure of the feedstock material in the final coating morphology, the use of novel thermal spray equipment as well as a thorough selection and optimization of the process parameters are fundamentally required. In this study, HVOF spray experiments have been conducted to manufacture fine structured, wear-resistant cermet coatings using fine 75Cr3C2-25(Ni20Cr) powders (-8 + 2 μm). Statistical design of experiments (DOE) has been utilized to identify the most relevant process parameters with their linear, quadratic and interaction effects using Plackett-Burman, Fractional-Factorial and Central Composite designs to model the deposition efficiency of the process and the majorly important coating properties: roughness, hardness and porosity. The concept of desirability functions and the desirability index have been applied to combine these response variables in order to find a process parameter combination that yields either optimum results for all responses, or at least the best possible compromise. Verification experiments in the so found optimum obtained very satisfying or even excellent results. The coatings featured an average microhardness of 1004 HV 0.1, a roughness Ra = 1.9 μm and a porosity of 1.7%. In addition, a high deposition efficiency of 71% could be obtained.

  1. Rotatable fixture for spray coating

    Science.gov (United States)

    Katvala, V.; Porter, E.; Smith, M.

    1979-01-01

    Fixture that rotates about two axes ensures uniform coating and minimizes handling of coated workpiece. Each side of tile is coated in sequence by moving turntables until surface is perpendicular to spray. Process is repeated until desired thickness has built up.

  2. Tailoring a High Temperature Corrosion Resistant FeNiCrAl for Oxy-Combustion Application by Thermal Spray Coating and HIP

    Directory of Open Access Journals (Sweden)

    Jarkko Metsäjoki

    2015-10-01

    Full Text Available Oxy-fuel combustion combined with CCS (carbon capture and storage aims to decrease CO2 emissions in energy production using fossil fuels. Oxygen firing changes power plant boiler conditions compared to conventional firing. Higher material temperatures and harsher and more variable environmental conditions cause new degradation processes that are inadequately understood at the moment. In this study, an Fe-Ni-Cr-Al alloy was developed based on thermodynamic simulations. The chosen composition was manufactured as powder by gas atomization. The powder was sieved into two fractions: The finer was used to produce thermal spray coatings by high velocity oxy-fuel (HVOF and the coarser to manufacture bulk specimens by hot isostatic pressing (HIP. The high temperature corrosion properties of the manufactured FeNiCrAl coating and bulk material were tested in laboratory conditions simulating oxy-combustion. The manufacturing methods and the results of high temperature corrosion performance are presented. The corrosion performance of the coating was on average between the bulk steel references Sanicro 25 and TP347HFG.

  3. Influence of Spraying Powers on Surface Free Energy and Tribological Properties of NiCr-Cr3C2 Coating%喷涂功率对NiCr-Cr3C2涂层表面自由能 及其摩擦性能的影响

    Institute of Scientific and Technical Information of China (English)

    李楠楠; 康嘉杰; 王海斗; 董天顺; 许中林; 李国禄

    2015-01-01

    The NiCr-Cr3C2 coatings are prepared by the supersonic plasma spraying under different spraying powers and the tribological properties are studied with surface free energy theory. By measuring the contact angles of the coating, the surface free energy and its components are calculated by the Owens-Wendt geometric mean method. By comparing the analysis, it finds that the porosity, micro-hardness and friction coefficient of the coating change as the spraying power, and the trend shows a certain similarity with the polar component. The analysis result indicates that the intermolecular force of surface is affected by the temperature and velocity of the flying particles under different spraying power. That indirectly changes the surface free energy and its components. When the change happened, the tribological properties of NiCr-Cr3C2 coating will be affected directly.%利用超音速等离子喷涂技术制备了不同喷涂功率条件下的NiCr-Cr3C2涂层,结合表面自由能理论研究了其表面摩擦学性能.利用 Owens-Wendt 几何平均法计算了涂层的表面自由能及其分量.对比发现,涂层孔隙率、显微硬度和摩擦因数均随着喷涂功率的变化而变化,且其变化趋势与极性分量均表现出一定的相似性.分析表明,受喷涂功率的影响,喷涂粒子的温度和速度对涂层表面分子间作用力产生影响,从而间接改变了涂层表面的自由能,并且自由能及其分量的改变,会直接影响NiCr-Cr3C2涂层表面的摩擦学特性.

  4. Comparative investigation on HVOF sprayed carbide-based coatings

    Science.gov (United States)

    Xie, Mingxiang; Zhang, Shihong; Li, Mingxi

    2013-05-01

    In this work, WC-17Co, WC-10Co-4Cr, WC-12Co and Cr3C2-25NiCr coatings were deposited on stainless steel using WOKAStar-640 HVOF spraying system. Three WC-based coatings were studied and compared with a chromium carbide-based coating. The microstructure, porosity, micro-hardness, indentation fracture toughness and adhesion strength of the coatings were investigated. The wear test was done by using silica grits as abrasive medium using a load of 20 N. The result shows that HVOF sprayed carbide-based coating possesses low porosity, high micro-hardness and high adhesion strength. Three WC-based coatings have higher micro-hardness and indentation fracture toughness compared to the Cr3C2-25NiCr coating. HVOF sprayed carbide coating has good wear resistance under 500 °C. The decarburization of WC-based coating has great effect on coating wear resistance. In addition, WC-17Co coating has best wear resistance.

  5. Influence of Feedstock Materials and Spray Parameters on Thermal Conductivity of Wire-Arc-Sprayed Coatings

    Science.gov (United States)

    Yao, H. H.; Zhou, Z.; Wang, G. H.; He, D. Y.; Bobzin, K.; Zhao, L.; Öte, M.; Königstein, T.

    2017-03-01

    To manufacture a protective coating with high thermal conductivity on drying cylinders in paper production machines, a FeCrB-cored wire was developed, and the spraying parameters for wire-arc spraying were optimized in this study. The conventional engineering materials FeCrAl and FeCrMo coatings were produced as the reference coatings under the same experimental condition. It has been shown that the oxide content in coating influences the thermal conductivity of coating significantly. The FeCrB coating exhibits a relative higher thermal conductivity due to the lower oxide content in comparison with conventional FeCrAl and FeCrMo coatings. Moreover, the oxidation of in-flight particles can be reduced by decreasing the standoff distance contributing to the increase in the thermal conductivity of coating. Total energy consumption of a papermaking machine can be significantly reduced if the coatings applied to dryer section exhibit high thermal conductivity. Therefore, the FeCrB coating developed in this study is a highly promising coating system for drying cylinders regarding the improved thermal conductivity and low operation costs in paper production industry.

  6. Influence of Feedstock Materials and Spray Parameters on Thermal Conductivity of Wire-Arc-Sprayed Coatings

    Science.gov (United States)

    Yao, H. H.; Zhou, Z.; Wang, G. H.; He, D. Y.; Bobzin, K.; Zhao, L.; Öte, M.; Königstein, T.

    2017-02-01

    To manufacture a protective coating with high thermal conductivity on drying cylinders in paper production machines, a FeCrB-cored wire was developed, and the spraying parameters for wire-arc spraying were optimized in this study. The conventional engineering materials FeCrAl and FeCrMo coatings were produced as the reference coatings under the same experimental condition. It has been shown that the oxide content in coating influences the thermal conductivity of coating significantly. The FeCrB coating exhibits a relative higher thermal conductivity due to the lower oxide content in comparison with conventional FeCrAl and FeCrMo coatings. Moreover, the oxidation of in-flight particles can be reduced by decreasing the standoff distance contributing to the increase in the thermal conductivity of coating. Total energy consumption of a papermaking machine can be significantly reduced if the coatings applied to dryer section exhibit high thermal conductivity. Therefore, the FeCrB coating developed in this study is a highly promising coating system for drying cylinders regarding the improved thermal conductivity and low operation costs in paper production industry.

  7. Microstructure and high temperature cyclic oxidation in atmospheres with variable oxygen contents of plasma and HVOF NiCrBSiFe sprayed coatings; Microestructura y oxidacion ciclica en atmosferas con contenidos de oxigeno variables de un recubrimiento NiCrBSiFe proyectado termicamente por plasma y HVOF

    Energy Technology Data Exchange (ETDEWEB)

    Higuera-Hidalgo, V.; Belzunce-Varela, F. J.; Riba-Lopez, J.

    2006-07-01

    The influence of thermal spraying procedure (plasma and HVOF) on the microstructure, high temperature oxidation resistance and adherence of NiCrSiFe coatings has been examined. Two different series of oxidation tests have been carried out in air (21% oxygen) at 800 and 1,000 degree centigree (1,073 y 1,273 K) and in a simulated gas turbine environment (10% oxygen) representative of a combined-cycle power generation plant, at the same temperatures. Coating microstructure, porosity, oxide content and microhardness are highly dependent on the spraying procedure and coating hardness also significantly decreases after long maintenance at high temperature (1,000 degree centigree). Finally, the oxidation weight gain and the adherence of NiCrBSiFe coatings are also dependent on the morphology of the coating but, nevertheless, the oxidation behaviour of these coatings was very good as protective chromium and silicon oxides were always formed. (Author) 14 refs.

  8. Characterisations of HVOF sprayed NiCrBSi coatings on Ni- and Fe-based superalloys and evaluation of cyclic oxidation behaviour of some Ni-based superalloys in molten salt environment

    Energy Technology Data Exchange (ETDEWEB)

    Sidhu, T.S. [Metallurgical and Materials Engineering Department, Indian Institute of Technology Roorkee, Roorkee-247667 (India)]. E-mail: tssidhu@rediffmail.com; Prakash, S. [Metallurgical and Materials Engineering Department, Indian Institute of Technology Roorkee, Roorkee-247667 (India); Agrawal, R.D. [Metallurgical and Materials Engineering Department, Indian Institute of Technology Roorkee, Roorkee-247667 (India)

    2006-09-25

    Microstructure plays a predominant role in determining material behaviour. Increasing microstructure uniformity has long been considered a fruitful means of improving thermal, chemical and mechanical properties of the materials. High velocity oxy-fuel (HVOF) is one of the emerging technologies among the thermal spraying techniques, for producing uniform and dense coatings, having high hardness and good adhesion values. In this study, HVOF technique was used to deposit NiCrBSi coatings, approximately 250-300 {mu}m thick, on the Ni- and Fe-based superalloys for hot corrosion applications. The coatings were characterised in relation to coating thickness, porosity, microhardness and microstructure. The hot corrosion behaviour of the coatings deposited on nickel-based superalloys after exposure to molten salt (Na{sub 2}SO{sub 4}-60% V{sub 2}O{sub 5}) at 900 deg. C under cyclic conditions was also studied. The techniques used in the present investigation include X-ray diffraction, optical microscopy, scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDAX) and electron probe microanalysis (EPMA). The thermogravimetric technique was used to establish kinetics of corrosion. The structure of the as sprayed NiCrBSi coating mainly consisted of {gamma}-nickel solid solution containing small fraction of Cr{sub 7}C{sub 3} and Ni{sub 3}B phases. Very weak peaks of NiCr{sub 2}O{sub 4} spinel oxides were also formed during spraying of the coatings. Some porosity (less than 1.4%) and inclusions were observed in the structure of the coatings. Coating microhardness values were found to be in the range of 750-930 Hv (Vickers Hardness) on different substrates. The NiCrBSi coating was found to be very effective in decreasing the corrosion rate in the given molten salt environment at 900 deg. C. The hot corrosion resistance imparted by NiCrBSi coatings may be attributed to the formation of oxides of silicon, chromium, nickel and spinels of nickel and chromium.

  9. The influence of the base material surface preparation on the properties of thermally sprayed coatings

    Directory of Open Access Journals (Sweden)

    V. Marušić

    2010-01-01

    Full Text Available Using specimens, a research was conducted to determine the influence of the base material surface preparation for 42CrMo4 on the final coating, prior to actual thermal spraying. During thermal spraying, an Al-Ni-alloy was used as an interlayer before the actual coating with Cr-Mo-Ni. The surface hardness and the hardness distribution across the thickness of the sprayed coating were measured and the structure of respective sprayed coatings was photographed. A comparison of experimental results enabled the identification of the particular material preparation method with an optimal ratio of the satisfactory coating thickness and its hardness.

  10. Tungsten carbide coatings with different binders prepared by low power plasma spray system

    Institute of Scientific and Technical Information of China (English)

    GAO Yang; M.F.Morks; FU Ying-qing

    2004-01-01

    Thermal spraying of cermet coatings is widely used for protection of machining parts against wear and corrosion. These coatings consist of WC particles in metal binders such as Co, Cr and Ni. Three kinds of WC powders with different metal binders (Co, NiCr and CoCr) were sprayed by low power plasma spray system on Al-Si-Cu alloy substrate. Fundamental aspects of sprayed cermet coatings, including (i) the effects of binder type on the coating structure, (ii) the hardness and (iii) the microstructure, were investigated. All cermet coatings have the same phase structure such as WC and W2 C. However, the intensities of these phases are different in each coating, mainly due to the difference in solidification rate in each case. Moreover, the hardness measurements are found to be different in each coating. The results show that, binder type has a significant effect on the physical and mechanical properties of the sprayed coatings.

  11. The Wear Behavior of HVOF Sprayed Near-Nanostructured WC-17%Ni(80/20)Cr Coatings in Dry and Slurry Wear Conditions

    Science.gov (United States)

    Ben Mahmud, Tarek A.; Atieh, Anas M.; Khan, Tahir I.

    2017-07-01

    The ability to deposit nanostructured feedstock by using high-velocity oxygen-fuel (HVOF) spray offers potential improvements in coating hardness, wear resistance and toughness for applications in the oil sands industry. In this study, the wear behavior of a near-nanostructured coating was compared under dry and slurry abrasive wear test using an uncoated AISI-1018 low-carbon steel substrate as a reference. The coating microstructures were analyzed in the as-sprayed, dry and slurry test conditions using scanning electron microscopy, x-ray diffraction and microhardness measurements. Wear behavior of the steel and coating surfaces were assessed using a pin-on-plate wear test under various loads. The results showed that a coating could be successfully deposited using the HVOF spraying technique and with retention of the near-nanosized WC dispersion within the coating structure. The wear rate under dry test conditions was greater for the steel and coating compared to tests performed under slurry conditions. Examination of the wear tracks revealed that the wear mechanism was different for the two test conditions. Wear in the dry test condition resulted from 2-body abrasion, while 3-body abrasion dominated wear in slurry conditions. The latter showed lower wear rates due to a lubricating effect of the oil.

  12. Microstructural and Mechanical Properties of Ni-Base Thermal Spray Coatings Deposited by Flame Spraying

    Science.gov (United States)

    Amokrane, Bradai Mohand; Abdelhamid, Sadeddine; Youcef, Mouadji; Abderrahim, Benabbas; Nedjemeddine, Bounar; Ahmed, Mammeri

    2011-10-01

    In this work, two different Ni-base powders, namely, ProXon 21021 (P21) and ProXon 21031 (P31), were sprayed onto a steel substrate 35CrMo4 using a thermal flame spray technique. The morphology and chemical composition of the phases that are present in the powders and coatings were characterized by using X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS). The hardness and wear resistance of the coatings were investigated. The XRD analysis revealed that the phases present in the coatings are different from the initial powders. In addition, some inhomogeneities such as oxides, porosity, and unmelted particles were observed by SEM. It was found that the P31 spray-coated exhibited higher microhardness, higher wear resistance, and significantly lower friction coefficient in comparison with those of P21 coatings.

  13. Dynamic residual stress in thermal sprayed coatings

    Institute of Scientific and Technical Information of China (English)

    Wang Zhiping; Yang Yuanyuan

    2005-01-01

    With the modified Almen method, the forming and development process of residual stress in a thermal sprayed coating has been obtained. The test results identify that the residual stress in a coating is depend on coating material properties, technique and coating thickness. The paper pays much attention to the hysteresis between the coating temperature and residual stress in the coating or between the applied stress and the strain of the coating, and confirms that the fact is resulted from the"Gas Fix" character of a thermal sprayed coating.

  14. The Corrosion and Wear Performance of Microcrystalline WC-10Co-4Cr and Near-Nanocrystalline WC-17Co High Velocity Oxy-Fuel Sprayed Coatings on Steel Substrate

    Science.gov (United States)

    Saha, Gobinda C.; Khan, Tahir I.

    2010-11-01

    The study of near-nanocrystalline cermet composite coating was performed by depositing near-nanocrystalline WC-17Co powder using the high velocity oxy-fuel spraying technique. The WC-17Co powder consists of a core with an engineered near-nano-scale WC dispersion with a mean grain size 427 nm. The powder particle contains 6 wt pct of the ductile phase Co matrix mixed into the core to ensure that the reinforcing ceramic phase WC material is discontinuous to limit debridement during wear, while the remainder of the binding phase (11 wt pct) is applied as a coating on the powder particle to improve the ductility. The tribological properties of the coating, in terms of corrosion resistance, microhardness, and sliding abrasive wear, were studied and compared with those of an industrially standard microcrystalline WC-10Co-4Cr coating with a WC mean grain size 3 μm. Results indicated that the WC-17Co coating had superior wear and corrosion resistance compared to the WC-10Co-4Cr coating. The engineered WC-17Co powder with a duplex Co layer had prevented significant decarburization of the WC dispersion in the coating, thereby reducing the intersplat microporosity necessary for initiating microgalvanic cells. The improved wear resistance was attributed to the higher hardness value of the near-nanocrystalline WC-17Co coating.

  15. Analysis of silt cavitation erosion resistance of Cr,C2/NiCr coating prepared by high velocity oxy-fuel thermal spraying%超音速火焰喷涂Cr3C2/NiCr涂层抗加沙空蚀性分析

    Institute of Scientific and Technical Information of China (English)

    王倩; 吴玉萍; 李改叶; 郭文敏

    2013-01-01

    采用HVOF技术在1Cr18Ni9Ti不锈钢基体上制备了Cr3C2/NiCr涂层,借助XRD,TEM,SEM等方法分析了涂层的组织形貌及相组成.以1Cr18Ni9Ti奥氏体不锈钢作为对比材料,用磁致伸缩空蚀仪配备扬沙装置测试了涂层在清水以及含沙水中抗空蚀性能.结果表明,涂层呈层状结构,含有未熔颗粒和少量孔隙,涂层由Cr3C2,Cr7C3,Cr23C6及NiCr等相组成;在清水试验中,1Cr18Ni9Ti不锈钢抗空蚀性能良好,与空蚀过程中1Cr18Ni9Ti奥氏体不锈钢产生加工硬化有直接关系;在含沙40 kg/m3试验水中,Cr3C2/NiCr涂层呈现出较好的抗空蚀性能,与涂层自身相组成以及较高硬度有关.Cr3C2/NiCr涂层破坏总是从孔隙等薄弱环节开始,而1Cr18Ni9Ti奥氏体不锈钢的破坏起始于晶界和孪晶界.%A Cr3C2/NiCr coating was prepared on 1Cr18Ni9Ti stainless steel by high velocity oxy-fuel (HVOF) thermal spraying. Phases and microstructures of the coating were analyzed by X-ray diffraction (XRD) , transmission electron microscope (TEM) and scanning election microscopy (SEM) , respectively. The cavitation erosion resistance and silt erosion resistance of the coating were evaluated under two experimental conditions (fresh water and water contained fine silt) , and compared with hydro machine material lCrl8Ni9Ti stainless steel. The result shows that the coating shows a layered structure and contains un-melted particles and some pores. The phases of the coating are composed of Cr3C2, Cr7C3, Cr23 C6 and NiCr. The 1Cr18Ni9Ti stainless steel produces the work hardening, which results in the resistance to cavitation erosion. The Cr3C2/NiCr coating exhibits significantly higher microhardness than 1Cr18Ni9Ti stainless steel, which leads to the resistance to silt erosion of the coating. The mass loss of the coating usually happens at the edges of the pores while the cavitation damage of the 1Cr18Ni9Ti stainless steel happens at the grain boundary and twin boundary.

  16. 超音速等离子喷涂FeCrBSi涂层组织和残余应力分析%Analysis of microstructure and residual stresses in supersonic plasma sprayed FeCrBSi coatings

    Institute of Scientific and Technical Information of China (English)

    王召煜; 李国禄; 王海斗; 刘金海; 徐滨士; 康嘉杰

    2012-01-01

    采用超音速等离子喷涂技术制备了FeCrBSi涂层,利用扫描电子显微镜(SEM)、X射线衍射仪(XRD)和纳米压痕仪等研究了涂层的微观组织和力学性能。采用X射线应力仪对不同厚度及不同温度退火后涂层的表面残余应力进行测试。结果表明涂层表面的残余应力为拉应力,且随着涂层厚度的增加而增加;对试样进行退火处理可以有效地缓和涂层表面的残余应力,随着温度的升高涂层表面的残余应力不断降低,到260℃左右变为压应力;压应力值随着退火温度的升高而变大,但当温度升高到大约400℃以上时,保持在80MPa左右。%FeCrBSi coatings on 45 steel were prepared by supersonic plasma spraying process. The microstructure, porosity and mechanical properties of the coatings were experimentally determined and analyzed by scanning electron microscopy( SEM), X-Ray diffraction(XRD) and nanoindention tester. The residual stresses in surface of the coatings with different thickness before and after annealing at different temperatures were measured by a X-ray residual stress measurement tester. Results demonstrate that residual stresses in surface of the coatings were tensile stress and increase with the increasing of thickness of coatings. Annealing treatment can effectively alleviate the residual stress. With the increasing of the annealing temperature, the tensile residual stress decreases obviously, is converted to compressive stress at about 260 ℃, and then increases with the increasing of the annealing temperature. But when the annealing temperature is over 400℃ the compresssive, and stress remains stable at about 80 MPa.

  17. 等离子喷涂Cr3C2/MoS2复合自润滑涂层的摩擦学性能%Investigation of Tribological Properties of Plasma Sprayed Cr3 C2/MoS2 Self-lubricating Coating

    Institute of Scientific and Technical Information of China (English)

    董衍林; 张磊; 董建东

    2011-01-01

    等离子喷涂工艺作为一种表面强化方法,已广泛应用于耐磨、减摩、耐蚀和耐高温等功能涂层的制备.采用等离子喷涂技术,在Q235钢表面制备Cr3C2和Cr3C2/MoS2复合自润滑涂层.对涂层的耐磨特性进行摩擦磨损实验研究,测定显微硬度,并分析涂层的微观结构和物相组成.结果表明,Cr3C2及Cr3C2/MoS2复合涂层的表面硬度平均提高近9倍;在室温干摩擦条件下,Cr3C2型喷涂层的抗磨性能比Q235基体有大幅度提高,加入一定量的MoS2即可维持Cr3C2型涂层的高硬度和抗磨损性能,又可有效降低摩擦因数.%As an important surface hardening method, the plasma spray shows its unique advantages in abrasion resistance, friction reduction, corrosion resistance and heat resistance functional coating preparation. The Cr3 C2 and Cr3 C2/MoS2 self-lubricating coatings were prepared on the surface of Q235 steel by a plasma spray process. Tribological properties of these coatings were investigated on a ring-block friction and wear tester. The microstructures, phases and micro-hardness were studied by SEM,XRD and micro-hardness meter. The experimental results show that the micro-hardness of Cr3C2 and Cr3C2/MoS2 self-lubricating coatings increases about 9 times compared to Q235 steel. At the conditions of the room temperature and dry friction, the wear resistance of Cr3C2-type plasma sprayed coating is greatly improved compared to Q235 steel. MoS2 can maintain the higher hardness and wear resistance, and reduce the friction coefficient of Cr3 C2-type plasma sprayed coating.

  18. Uniform spray coating for large tanks

    Science.gov (United States)

    Carter, J. M.

    1977-01-01

    System employs spray facility located within ventilated plastic booth to uniformly coat exterior of large cylindrical tanks with polyurethane foam insulation. Coating target is rotated on turntable while movable spray guns apply overlapping spirals of foam. Entire operation may be controlled by single operator from remote station.

  19. Screen-printed (La,Sr)CrO3 coatings on ferritic stainless steel interconnects for solid oxide fuel cells using nanopowders prepared by means of ultrasonic spray pyrolysis

    Science.gov (United States)

    Brylewski, Tomasz; Dabek, Jaroslaw; Przybylski, Kazimierz; Morgiel, Jerzy; Rekas, Mieczyslaw

    2012-06-01

    In order to protect the cathode from chromium poisoning and improve electrical resistance, a perovskite (La,Sr)CrO3 coating was deposited on the surface of a DIN 50049 ferritic stainless steel by means of the screen-printing method, using a paste composed of an ultra-fine powder prepared via ultrasonic spray pyrolysis. Investigations of the oxidation process of the coated steel in air and the Ar-H2-H2O gas mixture at 1073 K for times up to 820 h showed high compactness of the protective film, good adhesion to the metal substrate, as well as area specific resistance (ASR) at a level acceptable for metallic SOFC interconnect materials. The microstructure, nanostructure, phase composition of the thick film, and in particular the film/substrate interface, were examined via chemical analyses by means of SEM-EDS and TEM-SAD. It was shown that the (La,Sr)CrO3 coating interacts with the steel during long-term thermal oxidation in the afore-mentioned conditions and intermediate, chromia-rich and/or spinel multilayer interfacial zones are formed. Cr-vaporization tests showed that the (La,Sr)CrO3 coating may play the role of barriers that decrease the volatilization rate of chromia species.

  20. The change of NiCrBSi alloys’ phase composition after plasma spraying

    Directory of Open Access Journals (Sweden)

    A. Dudek

    2008-08-01

    Full Text Available Material for investigations was NiCrBSi powder for components’ coatings which improve their corrosion resistance as well as resistance to friction wear and erosion. Plasma spraying method was used to produce a coating with thickness of 300 μm on low-alloy steel which was then remelted with the base material. Using X-ray quality analysis, phase composition was determined for: NiCrBSi powder, obtained coating and the alloyed surface layer. Crystallinity degree was also calculated for NiCrBSi layer sprayed on the base material.

  1. Influence of Bond Coat on HVOF-Sprayed Gradient Cermet Coating on Copper Alloy

    Science.gov (United States)

    Ke, Peng; Cai, Fei; Chen, Wanglin; Wang, Shuoyu; Ni, Zhenhang; Hu, Xiaohong; Li, Mingxi; Zhu, Guanghong; Zhang, Shihong

    2017-06-01

    Coatings are required on mold copper plates to prolong their service life through enhanced hardness, wear resistance, and oxidation resistance. In the present study, NiCr-30 wt.%Cr3C2 ceramic-metallic (cermet) layers were deposited by high velocity oxy-fuel (HVOF) spraying on different designed bond layers, including electroplated Ni, HVOF-sprayed NiCr, and double-decker Ni-NiCr. Annealing was also conducted on the gradient coating (GC) with NiCr bond layer to improve the wear resistance and adhesion strength. Coating microstructure was investigated by scanning electron microscopy and x-ray diffraction analysis. Mechanical properties including microhardness, wear resistance, and adhesion strength of the different coatings were evaluated systematically. The results show that the types of metallic bond layer and annealing process had a significant impact on the mechanical properties of the GCs. The GCs with electroplated Ni bond layer exhibited the highest adhesion strength (about 70 MPa). However, the GC with HVOF-sprayed NiCr bond layer exhibited better wear resistance. The wear resistance and adhesion strength of the coating with NiCr metallic bond layer were enhanced after annealing.

  2. Young's Moduli of Cold and Vacuum Plasma Sprayed Metallic Coatings

    Science.gov (United States)

    Raj, S. V.; Pawlik, R.; Loewenthal, W.

    2009-01-01

    Monolithic metallic copper alloy and NiCrAlY coatings were fabricated by either the cold spray (CS) or the vacuum plasma spray (VPS) deposition processes. Dynamic elastic modulus property measurements were conducted on these monolithic coating specimens between 300 K and 1273 K using the impulse excitation technique. The Young's moduli decreased almost linearly with increasing temperature at all temperatures except in the case of the CS Cu-23%Cr-5%Al and VPS NiCrAlY, where deviations from linearity were observed above a critical temperature. It was observed that the Young's moduli for VPS Cu-8%Cr were larger than literature data compiled for Cu. The addition of 1%Al to Cu- 8%Cr significantly increased its Young's modulus by 12 to 17% presumably due to a solid solution effect. Comparisons of the Young s moduli data between two different measurements on the same CS Cu- 23%Cr-5%Al specimen revealed that the values measured in the first run were about 10% higher than those in the second run. It is suggested that this observation is due to annealing of the initial cold work microstructure resulting form the cold spray deposition process.

  3. The Hot Corrosion Performance of NiCr-Cr3 C2 Cermet Coating to Boiler Tube

    Institute of Scientific and Technical Information of China (English)

    DINGZhang-xiong; TUGuo-fu

    2004-01-01

    Three kinds of NiCr-Cr3 C2 cermet coatings were designed and deposited by the subsonic velocity flame spraying, and their performances of hot corrosion performance were evaluated in comt)arison with 102G,20G boiler tube steel, FeCrAl, NiCrTi, Ni5OCr and NiCrAIMoFe-Cr3 C2 coatings, which are widely used at present for protection of boiler tubes. Meanwhile, the influence of sealer on the hot corrosion resistance of warious coatings and the mechanisms of coating corrosion were explored.

  4. Properties of the ZrO2MgO/MgZrO3NiCr/NiCr triple-layer thermal barrier coating deposited by the atmospheric plasma spray process

    OpenAIRE

    Mihailo R. Mrdak

    2016-01-01

    This paper presents the results of the examinations of TBC - ZrO2MgO / MgZrO3NiCr / NiCr thermal barrier layers deposited by the plasma spray process at the atmospheric pressure on substrates of Al alloys. In order to obtain the structural and mechanical properties of layers, which will provide a good heat and abrasion protection of the tail elevators of aircraft J-22 when firing '.Lightning' and 'Thunder' rockets, the deposition of three powder types was performed on 0.6 mm thick Al alloy su...

  5. Microstructure and Sliding Wear Performance of Cr7C3-(Ni,Cr)3(Al,Cr) Coating Deposited from Cr7C3 In Situ Formed Atomized Powder

    Science.gov (United States)

    Zhu, Hong-Bin; Shen, Jie; Gao, Feng; Yu, Yueguang; Li, Changhai

    2017-01-01

    This work is aimed at developing a new type of Cr7C3-(Ni,Cr)3(Al,Cr) coating for parts used in heavy-duty diesel engines. The feedstock, in which the stripe-shaped Cr7C3 was in situ formed, was firstly prepared by vacuum melting and gas atomization and then subjected by high-velocity oxy-fuel spraying to form the coatings. The carbon content, microstructure and phase constitution of the powders, as well as the sprayed coatings, were analyzed by chemical analysis, SEM and XRD. The hardness and sliding wear performance of the sprayed coatings were also tested and compared to a commercial Cr3C2-NiCr coating used on piston rings. The results showed that the content of carbon in feedstock was almost the same as designed, and that the volume content of in situ formed Cr7C3 was increased with carbon and chromium added. The major phases of the powders and sprayed coatings are Cr7C3 and Cr-alloyed Ni3Al. Only a small amount of carbon lost during the spraying process. As Cr7C3 content increased in the coatings, the microhardness at room temperature was firstly increased to about 1000Hv0.3. The microhardness of the coatings stayed almost constant, while the testing temperature was raised up to 700 °C for 0.5 h, which illustrates the potential application of the investigated coatings under high temperature conditions. The coatings containing 70 and 77 vol.% Cr7C3 showed the most promising wear resistance, lower friction coefficient and better tribological compatibility to gray cast iron counterpart than other tested Cr7C3-(Ni,Cr)3(Al,Cr) coatings and the reference Cr3C2-NiCr coating.

  6. Microstructure and Sliding Wear Performance of Cr7C3-(Ni,Cr)3(Al,Cr) Coating Deposited from Cr7C3 In Situ Formed Atomized Powder

    Science.gov (United States)

    Zhu, Hong-Bin; Shen, Jie; Gao, Feng; Yu, Yueguang; Li, Changhai

    2016-12-01

    This work is aimed at developing a new type of Cr7C3-(Ni,Cr)3(Al,Cr) coating for parts used in heavy-duty diesel engines. The feedstock, in which the stripe-shaped Cr7C3 was in situ formed, was firstly prepared by vacuum melting and gas atomization and then subjected by high-velocity oxy-fuel spraying to form the coatings. The carbon content, microstructure and phase constitution of the powders, as well as the sprayed coatings, were analyzed by chemical analysis, SEM and XRD. The hardness and sliding wear performance of the sprayed coatings were also tested and compared to a commercial Cr3C2-NiCr coating used on piston rings. The results showed that the content of carbon in feedstock was almost the same as designed, and that the volume content of in situ formed Cr7C3 was increased with carbon and chromium added. The major phases of the powders and sprayed coatings are Cr7C3 and Cr-alloyed Ni3Al. Only a small amount of carbon lost during the spraying process. As Cr7C3 content increased in the coatings, the microhardness at room temperature was firstly increased to about 1000Hv0.3. The microhardness of the coatings stayed almost constant, while the testing temperature was raised up to 700 °C for 0.5 h, which illustrates the potential application of the investigated coatings under high temperature conditions. The coatings containing 70 and 77 vol.% Cr7C3 showed the most promising wear resistance, lower friction coefficient and better tribological compatibility to gray cast iron counterpart than other tested Cr7C3-(Ni,Cr)3(Al,Cr) coatings and the reference Cr3C2-NiCr coating.

  7. Plasma-Spray Metal Coating On Foam

    Science.gov (United States)

    Cranston, J.

    1994-01-01

    Molds, forms, and other substrates made of foams coated with metals by plasma spraying. Foam might be ceramic, carbon, metallic, organic, or inorganic. After coat applied by plasma spraying, foam left intact or removed by acid leaching, conventional machining, water-jet cutting, or another suitable technique. Cores or vessels made of various foam materials plasma-coated with metals according to method useful as thermally insulating containers for foods, liquids, or gases, or as mandrels for making composite-material (matrix/fiber) parts, or making thermally insulating firewalls in automobiles.

  8. Examining properties of arc sprayed nanostructured coatings

    Directory of Open Access Journals (Sweden)

    A. Czupryński

    2016-04-01

    Full Text Available The article presents the results of examining properties of arc sprayed coating obtained with nano-alloy on the iron matrix with a high amount of fine carbide precipitates sprayed on non-alloyed steel plates intended for high temperature operation. Powder metal cored wire EnDOtec DO*390N 1,6 mm diameter, was used to produce, dense, very high abrasion and erosion resistant coatings approx. 1,0 mm thick. Nano-material coatings characterization was done to determine abrasion resistance, erosion resistance, adhesion strength, hardness as well as metallographic examinations. Results have proved high properties of arc sprayed nano-material coatings and have shown promising industrial applications.

  9. Characteristics of Plasma-Sprayed Ceramic Coatings and Their Engineering Application

    Institute of Scientific and Technical Information of China (English)

    DENG Hua-ling; ZHANG Zhong-wen; WU Jun

    2004-01-01

    The microstructure, porosity, microhardness and adhesive strength of three plasma- sprayed ceramic coatings (Al2 O3, Cr2 O3 and Cr3 C2 + NiCr) were tested. The wear resistance of the coatings was characterized through sand blasting test. The results showed that the erosion resistance of Cr2 O3 coating was better than Al2 O3 and Cr3 C2 + NiCr coatings'.Through depositing the coating on the surface of boiler overheater tubes and on the surface of baffle- wall of carrying- coal grain blower to test its anti- erosion performance after a period of running, it was confirmed that the coatings present excellent wear resistance. Accordingly, it also demonstrates that ceramic coating has a promising prospects in surface protection in thermal power stations.

  10. Nano Cr Interlayered CrN Coatings on Steels

    Institute of Scientific and Technical Information of China (English)

    Gaoren Li; Pranav Deshpande; J. H. Li; R. Y. Lin

    2005-01-01

    CrN coated steels assisted with a nano Cr interlayer were investigated. The Cr nano-interlayers were prepared by sputter deposition with a thickness about 70-100 nm. CrN coatings were also prepared by sputter deposition on the Cr nano-interlayers. The crystal structures, microhardness, and scratch resistance of CrN/Cr coatings were determined. Results show that the Cr nano-interlayers improve scratch resistance and the microhardness of CrN coated steels. A rapid heat treatment with infrared (IR) was performed for coated specimens in the attempt to improve bonding. With IR heat treatments, the beneficial effect of the Cr nano-interlayers was clearly observed. Without the Cr nano-interlayers, severe cracks on the surface of coatings were observed after IR heat treatment. However, with a Cr interlayer, no cracks on the surface of CrN coatings were observed after the heat treatment. The scratch resistance of coatings was also affected by the Cr nano-interlayers. The scratch track was clean and showed significantly smaller amount of scratch debris for CrN coatings with Cr interlayers than those without the Cr nano-interlayers. The microhardness of coatings with the Cr nano-interlayers is higher than those without the Cr nano-interlayers after IR heat treatment. The Cr and CrN phase have been identified with X-ray diffraction analysis, and the results show that the higher the nitrogen content in the sputtering gas, the stronger the CrN peaks observed in the diffraction patterns are.

  11. Study on Preparation and Tribological Properties of Atmospheric Plasma-sprayed NiCoCrAlY/Al2 O3 Wear-resistant Coatings%等离子喷涂NiCoCrAlY/Al2 O3涂层的制备及摩擦性能研究

    Institute of Scientific and Technical Information of China (English)

    曹玉霞; 杜令忠; 张伟刚; 兰叶; 黄传兵

    2015-01-01

    ABSTRACT:Objective To prepare the atmospheric plasma-sprayed NiCoCrAlY/Al2 O3 wear-resistant coatings and study the tribo-logical properties and tribological mechanism of the coating. Methods The NiCoCrAlY/Al2 O3 composite powder was prepared by the technology of spray granulation, chemical and metallurgical coating and solid state alloying. The NiCoCrAlY/Al2 O3 composite coating was prepared by atmospheric plasma-spray technology using the prepared powder on the surface of 45# steel. The micro-structure and phase composition of the powder and coating were studied by SEM and XED. The tribological properties and tribologi-cal mechanism of the APS sprayed NiCoCrAlY/Al2 O3 composite coatings were investigated. Results The surface of Al2 O3 particles was evenly coated with NiCoCrAlY alloy and the thickness of NiCoCrAlY alloy was 3~5 μm. The composite coatings consisted of elongated lamellae and they integrated with each other very well. The phase compositions of composite powder were NiCrAl and Al2 O3 . The friction coefficient of the coating decreased with the increase of temperature. The friction coefficient of the coating was 0. 64 at room temperature and decreased to below 0. 4 at 800 ℃, which was due to the formation of metallic oxide. The wear rate of the coating first increased and then decreased with the increase of temperature. The abrasive mechanism of the NiCoCrAlY/Al2 O3 composite coatings was dominated by mixed brittle crack and abrasive at low temperature, and it was characterized by oxida-tion, abrasive, plastic deformation and as well as coating transfer to the coupled pin at high temperature. Conclusion The atmos-pheric plasma-sprayed NiCoCrAlY/Al2 O3 composite coating exhibited excellent wear-resistant performance by high temperature self-lubrication.%目的:制备等离子喷涂NiCoCrAlY/Al2 O3高温固体润滑耐磨涂层,并研究该涂层的摩擦性能和磨损机理。方法采用喷雾造粒、化工冶金包覆和固相合金化技术制备NiCoCr

  12. Residual stresses within sprayed coatings

    Institute of Scientific and Technical Information of China (English)

    JIANG Yi; XU Bin-shi; WANG Hai-dou

    2005-01-01

    Some important developments of residual stress researches for coating-based systems were studied. The following topics were included the sources of residual stresses in coatings: error analysis of Stoney's equation in the curvature method used for the measurement of coating residual stress, the modeling of residual stress and some analytical models for predicting the residual stresses in coatings. These topics should provide some important insights for the fail-safe design of the coating-based systems.

  13. Fullerene monolayer formation by spray coating.

    Science.gov (United States)

    Cervenka, J; Flipse, C F J

    2010-02-10

    Many large molecular complexes are limited in thin film applications by their insufficient thermal stability, which excludes deposition via commonly used vapour phase deposition methods. Here we demonstrate an alternative way of monolayer formation of large molecules by a simple spray coating method under ambient conditions. This technique has been successfully applied on C(60) dissolved in toluene and carbon disulfide. Monolayer thick C(60) films have been formed on graphite and gold surfaces at particular deposition parameters, as confirmed by atomic force and scanning tunnelling microscopies. Structural and electronic properties of spray coated C(60) films on Au(111) have been found comparable to thermally evaporated C(60). We attribute the monolayer formation in spray coating to a crystallization process mediated by an ultrathin solution film on a sample surface.

  14. Development of Oxidation Resistant Coatings on GRCop-84 Substrates by Cold Spray Process

    Science.gov (United States)

    Karthikeyan, J.

    2007-01-01

    GRCop-84, a Cu-CR-Nb alloy, has been developed for rocket engine liner applications. For maximum life additional oxidation protection is required to prevent blanching. NiCrAlY was identified as a suitable coating, and efforts were initiated to develop suitable coating techniques. Cold spray is one technique under consideration. Efforts at ASB Industries to produce dense, adherent coatings are detailed. The work culminated in the production of samples for testing at NASA Glenn Research Center.

  15. Thermal Spray Coatings for High-Temperature Corrosion Protection in Biomass Co-Fired Boilers

    Science.gov (United States)

    Oksa, M.; Metsäjoki, J.; Kärki, J.

    2015-01-01

    There are over 1000 biomass boilers and about 500 plants using waste as fuel in Europe, and the numbers are increasing. Many of them encounter serious problems with high-temperature corrosion due to detrimental elements such as chlorides, alkali metals, and heavy metals. By HVOF spraying, it is possible to produce very dense and well-adhered coatings, which can be applied for corrosion protection of heat exchanger surfaces in biomass and waste-to-energy power plant boilers. Four HVOF coatings and one arc sprayed coating were exposed to actual biomass co-fired boiler conditions in superheater area with a probe measurement installation for 5900 h at 550 and 750 °C. The coating materials were Ni-Cr, IN625, Fe-Cr-W-Nb-Mo, and Ni-Cr-Ti. CJS and DJ Hybrid spray guns were used for HVOF spraying to compare the corrosion resistance of Ni-Cr coating structures. Reference materials were ferritic steel T92 and nickel super alloy A263. The circulating fluidized bed boiler burnt a mixture of wood, peat and coal. The coatings showed excellent corrosion resistance at 550 °C compared to the ferritic steel. At higher temperature, NiCr sprayed with CJS had the best corrosion resistance. IN625 was consumed almost completely during the exposure at 750 °C.

  16. Characterization of Fe-Cr-B based coatings produced by HVOF and PTA processes

    Science.gov (United States)

    Kim, Hyung-Jun; Grossi, Stephanie; Kweon, Young-Gak

    1999-02-01

    Two Fe-Cr-B based gas atomized powders, Armacor M and 16, were thermally sprayed on a low carbon steel substrate, using the HVOF (High Velocity Oxygen Fuel) process. Armacor M was also weld-surfaced with the PTA (Plasma Transferred Arc) process. The resultant deposits were subsequently characterized, using X-ray diffraction, scanning electron microscopy, and microhardness measurement. The effects of heat treatment were also studied for HVOF-sprayed coatings. The wear performance of the coatings was investigated by two-body abrasive wear tests. The results of microstructural analysis of as-sprayed deposits revealed oxide and boride phases such as Fe3O4 and Cr1.65F0.35B0.96 in an α matrix for the HVOF-sprayed Armacor 16 coating, and only the boride phases (Cr1.65F0.35B0.96 and Cr2B) in an α matrix for the HVOFsprayed Armacor M coating. PTA weld-surfaced Armacor M coating contains needle-type long precipitates of Cr2B) and Cr1.65F0.35B0.96, in the α matrix. The hardness of the HVOF-sprayed Armacor 16 coating after heat treatment was substantially less than that of the as-sprayed coating due to the phase transformation from α to γ phase. Heat treatments of the HVOF-sprayed Armacor M coating did not produce changes in phase and its hardness decreased as compared to that of the as-sprayed coating. While HVOF-sprayed and PTA weld-surfaced Armacor M coatings have the same hardness, the latter shows better abrasive wear resistance because of the size and orientation of its boride phases. The broadening of the XRD patterns and the increase in hardness after wear testing suggest that the transformation from the crystalline to the amorphous structure occurred on the uppermost layer during wear testing.

  17. Interdiffusion between Co3O4 coating and the oxide scale of Fe-22Cr alloy

    DEFF Research Database (Denmark)

    Hansson, Anette Nørgaard; Friehling, Peter B.; Linderoth, Søren;

    2002-01-01

    on Fe-Cr alloys. Coatings of Co3O4 were deposited on a Fe-22Cr alloy by plasma spraying and spray-painting. As-deposited samples were oxidised in air containing 1% H2O at 900C for various exposure time. During exposure the Fe-22Cr alloy forms an oxide scale, which reacts with the coating. The effects...... of inter-diffusion between the oxide scale and the Co3O4 coating were investigated with X-ray diffraction, scanning electron microscopy and energy-dispersive spectroscopy. The results obtained are discussed in relation to a calculated Cr-Co-oxide phase diagrams....

  18. Hydroxyapatite coating on pretreated CoNiCrMo prosthesis

    Institute of Scientific and Technical Information of China (English)

    WANG Tao; A. Dorner-Reisel

    2005-01-01

    In order to improve the quality of the bio-active coating on medical grade CoNiCrMo substrate, hydroxyapatite(HA) coatings were produced via low-temperature dip-coating route on substrates treated using various surface pre-treating methods. The surface and cross-sectional morphologies of HA coatings were observed by SEM, as well as the bonding strength between coatings and substrates after different pre-treatments were characterized according to ASTM C633. The low-temperature HA dip-coating method with the substrate merely oxidized at 600℃ can provide a high quality HA coating for CoNiCrMo, of which the bonding strength reaches (58±5)MPa, higher than that of the clinically used HA coatings on Ti-alloys produced via plasma spray route, as well as a HA coating with full crystallinity and high phase-purity, which is more in-vivo stable than plasma sprayed HA coating.

  19. Laser treatment of plasma sprayed HA coatings

    NARCIS (Netherlands)

    Khor, KA; Vreeling, A; Dong, ZL; Cheang, P

    1999-01-01

    Laser treatment was conducted on plasma sprayed hydroxyapatite (HA) coatings using a Nd-YAG pulse laser. Various laser parameters were investigated. The results showed that the HA surface melted when an energy level of greater than or equal to 2 J and a spot size of 2 mm was employed during continuo

  20. Laser treatment of plasma sprayed HA coatings

    NARCIS (Netherlands)

    Khor, KA; Vreeling, A; Dong, ZL; Cheang, P

    1999-01-01

    Laser treatment was conducted on plasma sprayed hydroxyapatite (HA) coatings using a Nd-YAG pulse laser. Various laser parameters were investigated. The results showed that the HA surface melted when an energy level of greater than or equal to 2 J and a spot size of 2 mm was employed during continuo

  1. 热循环对锅炉管热喷涂Ni-Cr基纳米涂层的影响%Effect of thermal cycle on Ni-Cr based nanostructured thermal spray coating in boiler tubes

    Institute of Scientific and Technical Information of China (English)

    V.SENTHILKUMAR; B.THIYAGARAJAN; M.DURAISELVAM; K.KARTHICK

    2015-01-01

    采用机械球磨法制备Ni-Cr基纳米原料粉末.粉末颗粒在行星球磨机中反复经历焊合、碎裂和重焊合过程.采用超音速火焰喷涂工艺(HVOF)在碳钢管上喷涂球磨纳米粉末.利用金相显微镜、XRD、扫描电子显微镜(SEM),高分辨透射电子显微镜(HR-TEM)、能谱(EDS)和显微硬度测试对原料粉和HVOF喷涂涂层进行表征.对喷涂和未喷涂试样进行热循环分析,研究相、冶金性能和显微硬度的变化.与传统喷涂试样相比,Ni-Cr纳米涂层试样具有更高的力学和冶金性能.与传统涂层相比,纳米涂层的显微组织更均匀和紧密.%Ni-Cr based nanostructured feedstock powder was prepared by mechanical milling technique involving repeated welding, fracturing, and re-welding of powder particles in a planetary ball mill. The milled nanocrystalline powders were used to coat carbon steel tubes using high velocity oxygen fuel (HVOF) thermal spraying process. The characterization of the feedstock powder and HVOF coated substrates was performed using optical microscope, X-ray diffractometer (XRD), scanning electron microscope (SEM), high resolution transmission electron microscope (HR-TEM), energy dispersive spectrometer (EDS) and microhardness tests. The coated and uncoated samples were subjected to different thermal cycles and characterized for their phase changes, metallurgical changes and microhardness variations. Ni-Cr nanostructured coated samples exhibited higher mechanical and metallurgical properties compared to their conventionally coated counter parts. The results showed that the nanostructured coating possessed a more uniform and denser microstructure than the conventional coating.

  2. Characterization of High-Velocity Single Particle Impacts on Plasma-Sprayed Ceramic Coatings

    Science.gov (United States)

    Kiilakoski, Jarkko; Lindroos, Matti; Apostol, Marian; Koivuluoto, Heli; Kuokkala, Veli-Tapani; Vuoristo, Petri

    2016-08-01

    High-velocity impact wear can have a significant effect on the lifetime of thermally sprayed coatings in multiple applications, e.g., in the process and paper industries. Plasma-sprayed oxide coatings, such as Cr2O3- and TiO2-based coatings, are often used in these industries in wear and corrosion applications. An experimental impact study was performed on thermally sprayed ceramic coatings using the High-Velocity Particle Impactor (HVPI) at oblique angles to investigate the damage, failure, and deformation of the coated structures. The impact site was characterized by profilometry, optical microscopy, and scanning electron microscopy (SEM). Furthermore, the connection between the microstructural details and impact behavior was studied in order to reveal the damage and failure characteristics at a more comprehensive level. Differences in the fracture behavior were found between the thermally sprayed Cr2O3 and TiO2 coatings, and a concept of critical impact energy is presented here. The superior cohesion of the TiO2 coating inhibited interlamellar cracking while the Cr2O3 coating suffered greater damage at high impact energies. The HVPI experiment has proven to be able to produce valuable information about the deformation behavior of coatings under high strain rates and could be utilized further in the development of wear-resistant coatings.

  3. Long-Term Corrosion Testing of Thermal Spray Coatings of Amorphous Metals: Fe49.7Cr17.7Mn1.9Mo7.4W1.6B15.2C3.8Si2.4 and Fe48Mo14Cr15Y2C15B6

    Energy Technology Data Exchange (ETDEWEB)

    Farmer, J; Day, D; Lian, T; Saw, C; Hailey, P; Payer, J; Aprigliano, L; Beardsley, B; Branagan, D

    2007-07-09

    Amorphous alloys identified as SAM2X5 (Fe{sub 49.7}Cr{sub 17.7}Mn{sub 1.9}Mo{sub 7.4}W{sub 1.6}B{sub 15.2}C{sub 3.8}Si{sub 2.4}) and SAM1651 (Fe{sub 48}Mo{sub 14}Cr{sub 15}Y{sub 2}C{sub 15}B{sub 6}) have been produced as melt-spun ribbons, drop-cast ingots and thermal-spray coatings. Chromium (Cr), molybdenum (Mo) and tungsten (W) additions provided corrosion resistance, while boron (B) enabled glass formation. Earlier electrochemical studies of melt-spun ribbons and ingots of these amorphous alloys demonstrated outstanding passive film stability. More recently thermal-spray coatings of these amorphous alloys have been made and subjected to long-term salt-fog and immersion tests. Good corrosion resistance has been observed during salt-fog testing. Corrosion rates were measured in situ with linear polarization, while simultaneously monitoring the open-circuit corrosion potentials. Reasonably good performance was observed. The sensitivity of these measurements to electrolyte composition and temperature was determined. The high boron content of SAM2X5 also made it an effective neutron absorber, and suitable for criticality control applications.

  4. Corrosion behavior of HVOF sprayed hard face coatings in alkaline-sulfide solution

    Science.gov (United States)

    Li, Shenhou; Guo, Zhixing; Xiong, Ji; Lei, Yong; Li, Yuxi; Tang, Jun; Liu, Junbo; Ye, Junliu

    2017-09-01

    The paper focuses on the corrosion behavior of high velocity oxygen fuel (HVOF) sprayed WC-17Co, WC-10Co-4Cr, Cr3C2-25NiCr coatings in alkaline-sulfide solution (S2-, 0.2 ml/L, pH = 10). Eighteen days of immersion test is carried out and corrosion rate analysis shows that the Cr3C2-NiCr coating of low porosity exhibits the best corrosion resistance. In alkaline-sulfide solutions, porosity, passive film and microgalvanic between hard phase and binder phase have significant effect on the corrosion behavior of coatings. The corrosion mainly occurs in binder phase from SEM, though WO3, WS2, Cr2S3 are detected in XPS. In WC-17Co coating, the binder phase Co transforms to Co oxides and serious corrosion can be observed in binder phase. WC-10Co-4Cr coatings suffer localized corrosion since galvanic corrosion occurs between locations with different solubilities of W in Co binder. Cr3C2-25NiCr coating shows slight corrosion with the formation of NiS/Ni2O3/Cr2O3from the binder and Cr2S3 from the hard phase. The results are verified by the polarization curves, which show the longest passive region and lowest Icorrosion of Cr3C2-25NiCr coating.

  5. Study on Microstructure and Property of Low Pressure Plasma Sprayed MoB/CoCr Gradient Coatings by Laser Remelting%激光重熔低压等离子喷涂MoB/CoCr梯度涂层组织与性能研究

    Institute of Scientific and Technical Information of China (English)

    陈枭

    2012-01-01

    MoB/CoCr gradient coatings were sprayed on 310S stainless steel using low pressure plasma spraying method) and then MoB/CoCr gradient coatings were laser remelted. The microstructure and property of MoB/CoCr coatings were studied. Results show that the surface morphology of MoB/CoCr coating is smooth and dense, cross sectional microstucture of MoB/CoCr gradient coatings consists of dentrite crystal, cystiform crystal and flat crystal from the surface to the bottom of coatings; There is convection-diffusion phenomena occurred between element of 310S stainless steel and that of coatings, Fe element appears in the coatings; Microhardness of MoB/CoCr coating increases obviously after laser remelting.%采用低压等离子喷涂技术在310S不锈钢表面制备MoB/CoCr梯度涂层,然后对MoB/CoCr涂层进行激光重熔处理,对重熔后涂层的组织结构及性能进行了研究.研究结果表明,激光重熔后,涂层表面平整致密,截面的显微组织呈树枝晶-胞状晶-平面晶过渡;激光重熔过程中,微熔的310S基体元素与熔化的涂层元素发生对流扩散现象,涂层中出现Fe元素成分;激光重熔后,MoB/CoCr层的硬度明显提高.

  6. Convergent spray process for environmentally friendly coatings

    Science.gov (United States)

    Scarpa, Jack

    1995-01-01

    Conventional spray application processes have poor transfer efficiencies, resulting in an exorbitant loss in materials, solvents, and time. Also, with ever tightening Environmental Protection Agency (EPA) regulations and Occupational Safety and Health Administration requirements, the low transfer efficiencies have a significant impact on the quantities of materials and solvents that are released into the environment. High solids spray processes are also limited by material viscosities, thus requiring many passes over the surface to achieve a thickness in the 0.125 -inch range. This results in high application costs and a negative impact on the environment. Until recently, requirements for a 100 percent solid sprayable, environmentally friendly, lightweight thermal protection system that can be applied in a thick (greater than 0.125 inch) single-pass operation exceeded the capability of existing systems. Such coatings must be applied by hand lay-up techniques, especially for thermal and/or fire protection systems. The current formulation of these coatings has presented many problems such as worker safety, environmental hazards, waste, high cost, and application constraints. A system which can apply coatings without using hazardous materials would alleviate many of these problems. Potential applications include the aerospace thermal protective specialty coatings, chemical and petroleum industries that require fire-protection coatings that resist impact, chemicals, and weather. These markets can be penetrated by offering customized coatings applied by automated processes that are environmentally friendly.

  7. Laser Remelting of Plasma Sprayed Thermal Barrier Coatings

    Institute of Scientific and Technical Information of China (English)

    Gang ZHANG; Yong LIANG; Yingna WU; Zhongchao FENG; Bingchun ZHANG; Fangjun LIU

    2001-01-01

    A CO2 continuous wave laser with defocused beam was used for remelting the surface of plasma sprayed ZrO2-8 wt pct Y2O3 (8YSZ)/Ni22Cr10AlY thermal barrier coatings (TBCs) on GH536 superalloy substrate. Two main laser processing parameters, power and travel speed, were adopted to produce a completely remelted layer, and their effects on remelted appearance,remelting depth, density and diameter of depression, space of segment crack and remelted microstructure were evaluated. With energy of 4.0 to 8.0 J.mm-2, an appropriate laser processing for applicable remelted layer was suggested.

  8. The erosion performance of cold spray deposited metal matrix composite coatings with subsequent friction stir processing

    Science.gov (United States)

    Peat, Tom; Galloway, Alexander; Toumpis, Athanasios; McNutt, Philip; Iqbal, Naveed

    2017-02-01

    This study forms an initial investigation into the development of SprayStir, an innovative processing technique for generating erosion resistant surface layers on a chosen substrate material. Tungsten carbide - cobalt chromium, chromium carbide - nickel chromium and aluminium oxide coatings were successfully cold spray deposited on AA5083 grade aluminium. In order to improve the deposition efficiency of the cold spray process, coatings were co-deposited with powdered AA5083 using a twin powder feed system that resulted in thick (>300 μm) composite coatings. The deposited coatings were subsequently friction stir processed to embed the particles in the substrate in order to generate a metal matrix composite (MMC) surface layer. The primary aim of this investigation was to examine the erosion performance of the SprayStirred surfaces and demonstrate the benefits of this novel process as a surface engineering technique. Volumetric analysis of the SprayStirred surfaces highlighted a drop of approx. 40% in the level of material loss when compared with the cold spray deposited coating prior to friction stir processing. Micro-hardness testing revealed that in the case of WC-CoCr reinforced coating, the hardness of the SprayStirred material exhibits an increase of approx. 540% over the unaltered substrate and 120% over the as-deposited composite coating. Microstructural examination demonstrated that the increase in the hardness of the MMC aligns with the improved dispersion of reinforcing particles throughout the aluminium matrix.

  9. Plasma Spray Forming of Nanostructured Composite Coatings

    Institute of Scientific and Technical Information of China (English)

    2002-01-01

    The nanostructure composite coating is obtained via plasma spraying of Al2O3-13 wt pct TiO2 powder. Brittle and hard lamella results from melted nanostructured powder. Ductile nanostructured matrix forms from unmelted nanostructured particles. Through the adjustment of constituent and nanostructure, hardness/strength and toughness/ductility are balanced and overall properties of the structure composite are achieved.

  10. Suspension plasma sprayed composite coating using amorphous powder feedstock

    Science.gov (United States)

    Chen, Dianying; Jordan, Eric H.; Gell, Maurice

    2009-03-01

    Al 2O 3-ZrO 2 composite coatings were deposited by the suspension plasma spray process using molecularly mixed amorphous powders. X-ray diffraction (XRD) analysis shows that the as-sprayed coating is composed of α-Al 2O 3 and tetragonal ZrO 2 phases with grain sizes of 26 nm and 18 nm, respectively. The as-sprayed coating has 93% density with a hardness of 9.9 GPa. Heat treatment of the as-sprayed coating reveals that the Al 2O 3 and ZrO 2 phases are homogeneously distributed in the composite coating.

  11. Hot Corrosion Behavior of HVOF Sprayed Coatings on ASTM SA213-T11 Steel

    Science.gov (United States)

    Sidhu, H. S.; Sidhu, B. S.; Prakash, S.

    2007-09-01

    Cr3C2-NiCr, NiCr, WC-Co and Stellite-6 alloy coatings were sprayed on ASTM SA213-T11 steel using the HVOF process. Liquid petroleum gas was used as the fuel gas. Hot corrosion studies were conducted on the uncoated as well as HVOF sprayed specimens after exposure to molten salt at 900 °C under cyclic conditions. The thermo-gravimetric technique was used to establish the kinetics of corrosion. XRD, SEM/EDAX and EPMA techniques were used to analyze the corrosion products. All these overlay coatings showed a better resistance to hot corrosion as compared to that of uncoated steel. NiCr Coating was found to be most protective followed by the Cr3C2-NiCr coating. WC-Co coating was least effective to protect the substrate steel. It is concluded that the formation of Cr2O3, NiO, NiCr2O4, and CoO in the coatings may contribute to the development of a better hot-corrosion resistance. The uncoated steel suffered corrosion in the form of intense spalling and peeling of the scale, which may be due to the formation of unprotective Fe2O3 oxide scale.

  12. Cr-Free Metallic-Ceramic Coatings

    Science.gov (United States)

    2014-11-01

    Cr -FREE METALLIC-CERAMIC COATINGS ASETS Defense 2014 Fort Myer, VA, November 18-20, 2014 Bruce McMordie Coatings for Industry 319...SNECMA Alseal® 5K Aluminum-Silicate Al-Silicate Coating System Now Available That Can Eliminate Hazards of Carcinogenic Cr +6 in Al...OMB control number. 1. REPORT DATE NOV 2014 2. REPORT TYPE 3. DATES COVERED 00-00-2014 to 00-00-2014 4. TITLE AND SUBTITLE Cr -Free Metallic

  13. Direct morphological comparison of vacuum plasma sprayed and detonation gun sprayed hydroxyapatite coatings for orthopaedic applications.

    Science.gov (United States)

    Gledhill, H C; Turner, I G; Doyle, C

    1999-02-01

    Hydroxyapatite coatings on titanium substrates were produced using two thermal spray techniques vacuum plasma spraying and detonation gun spraying. X-ray diffraction was used to compare crystallinity and residual stresses in the coatings. Porosity was measured using optical microscopy in conjunction with an image analysis system. Scanning electron microscopy and surface roughness measurements were used to characterise the surface morphologies of the coatings. The vacuum plasma sprayed coatings were found to have a lower residual stress, a higher crystallinity and a higher level of porosity than the detonation gun coatings. It is concluded that consideration needs to be given to the significance of such variations within the clinical context.

  14. High Temperature Oxidation Behavior of HVOF-sprayed Coatings for Use in Thixoextrusion Processes

    Science.gov (United States)

    Picas, J. A.; Punset, M.; Menargues, S.; Campillo, M.; Baile, M. T.; Forn, A.

    2011-05-01

    The dies used for the thixoextrusion of steels have to be capable of withstanding complex thermal and mechanical loads, while giving a sufficient wear resistance against abrasion and adhesion at very high temperatures. In order to improve the wear resistance and reduce the heating of the extrusion die it can be protected with a hard cermet coating. The purpose of this work is to study the high-temperature performance of CrC-CoNiCrAlY coating and explore the potential application of this coating to improve dies used in thixoextrusion processes. A two-layer 75CrC-25CoNiCrAlY coating with a CoNiCrAlY bond-coating was fabricated by the HVOF thermal spray process on a steel substrate. Coatings were heat-treated at a range of temperatures between 900 °C and 1100 °C. The microstructural characterization of the coatings before and after heat treatment was conducted by scanning electron microscopy (SEM) and an X-ray diffractometer (XRD). The mechanical properties of coatings were determined as a function of the temperature of heat treatment. The bond coat effect on the thermal shock resistance of CrC-CoNiCrAlY coating was analyzed.

  15. Coating Properties of WC-Ni Cold Spray Coating for the Application in Secondary Piping System of Nuclear Power Plants

    Energy Technology Data Exchange (ETDEWEB)

    Kim, JeongWon; Kim, Seunghyun; Kim, Ji Hyun [UNIST, Ulsan (Korea, Republic of)

    2015-10-15

    As a result of FAC(flow accelerated corrosion), severe accidents, failure of carbon steel like a Mihama Unit-3 occurred. Chemical composition change of carbon steel or coating to inner surface is one of methods to improve corrosion properties. Among them, thermal spray coating is convenient solution to apply at industry. Powder is melted at blast furnace and ejected to substrate. After adhesion, substrate and coating layer is cooled down and coated layer protects steel from corrosion finally. However high thermal energy is transferred to substrate and coating layer so it leads high thermal residual stress in coating procedure. Besides, high temperature for melting powder makes unexpected chemical reaction of powder like an oxidation or carburization. Whereas, cold spray uses low temperature comparing with other thermal spray. Thermal energy is used for not melting powder but high kinetic energy of powder and plastic deformation during collision. Therefore, fuel such as oxygen-acetylene gas is not needed. It needs carrier gas, compressed air, nitrogen or helium, to increase kinetic energy of powder and move powder to substrate. Comparing cold spray with high velocity oxy fuel (HVOF), one of thermal spray, cold spray coating layer contains only WC and Co. One of other problem about WC is brittleness during coating. To improve deformability of WC, binder metal is added. For example, Co, Cr, Ni, Cu, Al, Fe or etc. Additionally, binder metal lowering melting temperature of composite powder increases coating properties. Among them, Co which is widely used as binder metal maintains mechanical properties like a hardness and improves corrosion properties. Therefore Co is not suitable for binder metal of WC coating. In contrast, Ni has better corrosion resistance to alkaline environment and makes lower melting temperature. Moreover, in a view of cold spray, FCC structure has better deformability than BCC or HCP, and BCC has lowest deformability. WC is BCC structure so it

  16. Resistance of Cavitation Erosion of HVOF Sprayed WC-Co( Cr) Coating in NaCl Solution%超音速火焰喷涂WC-Co(Cr)涂层在NaCl溶液中抗空蚀性能研究

    Institute of Scientific and Technical Information of China (English)

    丁彰雄; 石琎; 丁翔; 胡一鸣; 廖星文; 邓帮华

    2016-01-01

    Two micro-structured WC-10Co4Cr cermet coatings and a nano-structured WC-12Co cermet coating are deposited by high velocity Oxy-fuel spray ( HVOF) , and the morphologies and structures of the coatings are analyzed by SEM .The coatings'porosity , fracture toughness and microhardness are measured .The CorrTest electrochemical testing system is used to analyze the electrochemical corrosion properties of the coatings .Resistance of coatings to cavitation erosion is studied by ultrasonic vibration cavitation equipment in 3.5wt%NaCl solution and the cavitation mechanisms are explored .It is shown that the nano-structured WC-12Co coating deposited by high velocity oxygen liquid fuel spray has lowest porosity and the densest microstructure , and frac-ture toughness is significantly higher than that of micron-structured WC-10Co4Cr coatings.Although the micron-structured WC-10Co4Cr cermet coating deposited by high velocity fuel oxygen liquid spray has coarser particles than the nano -structured, it ex-hibits the most excellent corrosion and cavitation erosion resistance .The cavitation rate is approximately one quarter that of the nano-structured WC-12Co cermet coating in 3.5wt%NaCl solution.%采用超音速火焰喷涂(HVOF)工艺制备2种微米结构WC-10Co4Cr及1种纳米结构WC-12Co金属陶瓷复合涂层;采用SEM分析涂层的组织结构;测量了涂层的显微硬度、孔隙率及开裂韧性;采用CorrT-est电化学测试系统分析涂层的电化学腐蚀性能;采用超声振动空蚀装置研究涂层在质量分数为3.5% NaCl溶液中的抗空蚀性能,探讨涂层的空蚀机理. 结果表明:使用液体燃料HVOF工艺喷涂的纳米WC-12Co涂层组织结构最细小,孔隙率最低,显微硬度和开裂韧性明显高于液体燃料和气体燃料HVOF工艺喷涂的微米WC-10Co4Cr涂层;采用液体燃料HVOF工艺喷涂的微米结构WC-10Co4Cr涂层在质量分数为3.5%NaCl溶液中显示了最优异的抗腐蚀和抗空蚀

  17. Cold Sprayed Intermetallic Thermal Barrier Coatings

    Science.gov (United States)

    Leshchinsky, Evgeny

    Conventional thermal barrier coating (TBC) systems consist of a duplex structure with a metallic bond coat and a ceramic heat-isolative topcoat. Several recent research activities are concentrated on the development of improved multilayer bond coat and TBC materials. This study represents an investigation performed for the aluminum based bond coats, especially those with reduced thermal conductivities. Using alternative TBC materials, such as metal alloys and intermetallics, their processing methods can be further optimized to achieve the best thermal physical parameters. One example is the ten-layer system in which cold sprayed aluminum based intermetallics are synthesized. These systems demonstrated improved heat insulation and thermal fatigue capabilities compared to conventional TBC. The microstructures and properties of the laminar coatings were characterized by SEM, EDS, XRD; micromechanical and durability tests were performed to define the structure and coating formation mechanisms. Application prospects for HCCI engines are discussed. Fuel energy can be utilized more efficiently with the concept of low heat rejection engines with applied TBC.

  18. Thermal Spray Formation of Polymer Coatings

    Science.gov (United States)

    Coquill, Scott; Galbraith, Stephen L.; Tuss. Darren L.; Ivosevic, Milan

    2008-01-01

    This innovation forms a sprayable polymer film using powdered precursor materials and an in-process heating method. This device directly applies a powdered polymer onto a substrate to form an adherent, mechanically-sound, and thickness-regulated film. The process can be used to lay down both fully dense and porous, e.g., foam, coatings. This system is field-deployable and includes power distribution, heater controls, polymer constituent material bins, flow controls, material transportation functions, and a thermal spray apparatus. The only thing required for operation in the field is a power source. Because this method does not require solvents, it does not release the toxic, volatile organic compounds of previous methods. Also, the sprayed polymer material is not degraded because this method does not use hot combustion gas or hot plasma gas. This keeps the polymer from becoming rough, porous, or poorly bonded.

  19. 等离子喷涂Cr3C2-NiCr涂层的Vickers硬度研究%STUDY ON VICKERS HARDNESS OF PLASMA SPRAYED Cr3C2-NiCr COATING

    Institute of Scientific and Technical Information of China (English)

    李剑锋; 丁传贤

    2000-01-01

    研究了等离子喷涂Cr3C2-NiCr涂层的Vickers硬度服从正态分布、对数正态分布和Weibull分布的拟合优度,在统计分析的基础上,考察了压头载荷和测量位置对涂层Vickers硬度的影响.结果表明:涂层的Vickers硬度同时显著地服从正态分布、对数正态分布和Weibull分布,根据不同分布估计出的平均值的置信区间大致相同;由于压痕的弹性恢复,并且涂层中存在有一定量的气孔、微裂纹、层状颗粒界面和氧化物夹杂等,随着载荷的增加,涂层Vickers硬度的平均值减小,但数据的均匀性增加;涂层-基材界面附近和涂层外边缘部位的Vickers硬度明显低于涂层主体部分的Vickers硬度,这与涂层的气孔率分布有关;在涂层横截面上易发生层间裂纹扩展,在横截面上测得的Vickers硬度小于在涂层表面方向上测得的Vickers硬度.

  20. Effects of Process Conditions on Fretting Wear Properties of Thermal Sprayed NiCr/WC Nanostructured Coating%喷涂工艺参数对热喷涂纳米镍铬碳化钨涂层微动磨损性能的影响

    Institute of Scientific and Technical Information of China (English)

    刘胜林; 郑雪萍

    2012-01-01

    以纳米NiCr/WC复合粉末(其中70%的WC与30%的NiCr)(文中含量均为质量分数)为原料,采用活性燃烧超音速火焰喷涂技术制备了纳米NiCr/WC复合涂层.利用SRV高温磨损试验机进行微动磨损试验,结果显示,在其它工艺参数相同的条件下,纳米涂层在喷涂距离为200 mm条件下的耐磨性能最差,在喷涂距离为160 mm条件下的耐磨性能最好;纳米涂层在送粉率为5 rpm条件下的耐磨性能最差,在送粉率为15 rpm条件下的耐磨性能最好.此外,与综合性能优良的渗碳轴承钢20CrNi2Mo相比,所有的纳米涂层的耐磨损性能都明显优于相同温度条件下的轴承钢的耐磨损性能.%Nanostructured coatings of NiCr/WC (70% WC, 30%NiCr) were prepared via actived-combustion-high velocity air fuel (AC-HVAF). Fretting wear test was carried out by SRV high, temperature wearing equipment The results show that the thermal sprayed NiCr/WC nanostructured coating prepared from the spraying distance of 160 mm has the best fretting wear properties under the same other process parameters, and the nanostructured coating prepared from the spraying distance of 200 mm has the worst fretting wear properties. The nanostructured coating prepared at the powder feed rate of 15 rpm has the best fretting wear properties under the same other process parameters, the nanostructured coating prepared at the powder feed rate of 5 rpm has the worst fretting wear properties, respectively. In addition, compared to the carburizing bearing steel 20CrNi2Mo with excellent overall performance, the wearing resistances of all nanostructured coatings are better than that of the carburizing bearing steel under the same wear conditions.

  1. Superhydrophobic Ceramic Coatings by Solution Precursor Plasma Spray

    Science.gov (United States)

    Cai, Yuxuan; Coyle, Thomas W.; Azimi, Gisele; Mostaghimi, Javad

    2016-04-01

    This work presents a novel coating technique to manufacture ceramic superhydrophobic coatings rapidly and economically. A rare earth oxide (REO) was selected as the coating material due to its hydrophobic nature, chemical inertness, high temperature stability, and good mechanical properties, and deposited on stainless steel substrates by solution precursor plasma spray (SPPS). The effects of various spraying conditions including standoff distance, torch power, number of torch passes, types of solvent and plasma velocity were investigated. The as-sprayed coating demonstrated a hierarchically structured surface topography, which closely resembles superhydrophobic surfaces found in nature. The water contact angle on the SPPS superhydrophobic coating was up to 65% higher than on smooth REO surfaces.

  2. Plasma spray deposition of graded metal-ceramic coatings

    Energy Technology Data Exchange (ETDEWEB)

    Musil, J. (Inst. of Tech. and Reliability of Structures, Czechoslovak Academy of Sciences, Plzen (Czechoslovakia)); Fiala, J. (Central Research Inst., Plzen (Czechoslovakia))

    1992-05-20

    Plasma spraying of graded coatings is described and the metal-ceramic interface of the graded intermediate zone is analysed in terms of a simple physical model. Special attention is devoted to the dominant deposition parameters, powder characteristics and the injector configuration for powder feeding, which play a fundamental role in graded coating deposition with controlled formation of a metal-ceramic intermediate zone. On the basis of a knowledge of these parameters, a new and original formula for the coefficient of homogeneity for simultaneous deposition of metal and ceramic particles at the same spot on the substrate is derived. Furthermore, very interesting topotactical relations are described for the metal-ceramic interface of the graded zone. Various techniques of structural analysis (X-ray diffraction, scanning electron microscopy, optical microscopy) and simple thermodynamic calculations allow a new interpretation to be given of the bonding between the metal and ceramic components. The cohesion of graded metal-ceramic coatings is predicted to be higher than that of ceramic coatings with a metallic bond layer. The results are illustrated by a NiCr-ZrO{sub 2}(MgO) graded coating. (orig.).

  3. Characteristics of MCrAlY coatings sprayed by high velocity oxygen-fuel spraying system

    Energy Technology Data Exchange (ETDEWEB)

    Itoh, Y.; Saitoh, M.; Tamura, M.

    2000-01-01

    High velocity oxygen-fuel (HVOF) spraying system in open air has been established for producing the coatings that are extremely clean and dense. It is thought that the HVOF sprayed MCrAlY (M is Fe, Ni and/or Co) coatings can be applied to provide resistance against oxidation and corrosion to the hot parts of gas turbines. Also, it is well known that the thicker coating can be sprayed in comparison with any other thermal spraying systems due to improved residual stresses. However, thermal and mechanical properties of HVOF coatings have not been clarified. Especially, the characteristics of residual stress, that are the most important property from the view point of production technique, have not been made clear. In this paper, the mechanical properties of HVOF sprayed MCrAlY coatings were measured in both the case of as-sprayed and heat-treated coatings in comparison with a vacuum plasma sprayed MCrAlY coatings. It was confirmed that the mechanical properties of HVOF sprayed MCrAlY coatings could be improved by a diffusion heat treatment to equate the vacuum plasma sprayed MCrAlY coatings. Also, the residual stress characteristics were analyzed using a deflection measurement technique and a X-ray technique. The residual stress of HVOF coating was reduced by the shot-peening effect comparable to that of a plasma spray system in open air. This phenomena could be explained by the reason that the HVOF sprayed MCrAlY coating was built up by poorly melted particles.

  4. Determination of residual stresses within plasma spray coating using Moiré interferometry method

    Science.gov (United States)

    Yi, Jiang; Bin-shi, Xu; Hai-dou, Wang; Ming, Liu; Yao-hui, Lu

    2011-01-01

    In this paper, residual stresses of the Ni-Cr-B-Si coatings prepared by supersonic plasma spray processing were measured by moiré interferometry and X-ray diffraction method. Moiré interferometry method was used in measuring the distribution of residual stresses of the Ni-Cr-B-Si coatings alongside the specimen thickness direction, then the distribution of residual stresses both in the substrate and the coating was also analyzed. Experimental results showed that residual stresses in the coating and the substrate are tensile and compressive separately; residual stresses of the coating are diminished with the increase of the distance from the coating surface and almost zero at the coating-substrate interface; the maximum of compressive residual stresses of the substrate are present to the vicinity of the coating-substrate interface. It could be concluded that residual stresses in the specimen would result from the dismatch of thermophysical properties between the coating and substrate during the spray process, and the distribution of residual stresses of the substrate would be influenced by the sandblasting prior to spraying.

  5. Spray applicator for spraying coatings and other fluids in space

    Science.gov (United States)

    Kuminecz, J. F.; Lausten, M. F. (Inventor)

    1985-01-01

    A self contained spray application is developed for one handed operation in a zero gravity vacuum environment by a free flying astronaut not attached to any spacecraft. This spray applicator eliminates contamination of the operator by back spray. This applicator includes a rigid accumulator containment of a fluid within a flexible bladder the fluid being urged out of the accumulator under pressure through a spray gun. The spray gun includes a spring loaded lockable trigger which controls a valve. When in an open position, the fluid passes through the valve into the ambient environment in the form of a spray. A spray shield is provided which directs the flow of the spray from the applicator by trapping errant particles of spray yet allowing the passage of escaping gases through its material.

  6. Electrochemical Characterization of Multilayer Cr/CrN-Based Coatings

    Directory of Open Access Journals (Sweden)

    Fabio C. Caiazzo

    2014-07-01

    Full Text Available In this work, a series of mono-and multilayer coatings were considered. They consisted of CrN and Cr prepared by physical vapor deposition with a cathodic arc. The most common steels for molds of plastics were chosen as substrates: X37CrMoV5-1 (SMV3, X2NiCoMo18-8-5 (MARVAL M1, X105CrCoMo18-2 (N690 and X40CrMo15 (X13T6. The samples were made with surface state conditions reproducing the main finishes required for molding of plastics: mirror, electro-eroded, sandblasted and ground finish. The coatings were characterized morphologically and chemically. The corrosion behavior of bare and coated steels was evaluated by electrochemical methods.

  7. Efficient spray-coated colloidal quantum dot solar cells

    KAUST Repository

    Kramer, Illan J.

    2014-11-10

    (Figure Presented). A colloidal quantum dot solar cell is fabricated by spray-coating under ambient conditions. By developing a room-temperature spray-coating technique and implementing a fully automated process with near monolayer control - an approach termed as sprayLD - an electronic defect is eliminated resulting in solar cell performance and statistical distribution superior to prior batch-processed methods along with a hero performance of 8.1%.

  8. Fireside Corrosion Behavior of HVOF and Plasma-Sprayed Coatings in Advanced Coal/Biomass Co-Fired Power Plants

    Science.gov (United States)

    Hussain, T.; Dudziak, T.; Simms, N. J.; Nicholls, J. R.

    2013-06-01

    This article presents a systematic evaluation of coatings for advanced fossil fuel plants and addresses fireside corrosion in coal/biomass-derived flue gases. A selection of four candidate coatings: alloy 625, NiCr, FeCrAl and NiCrAlY were deposited onto superheaters/reheaters alloy (T91) using high-velocity oxy-fuel (HVOF) and plasma spraying. A series of laboratory-based fireside corrosion exposures were carried out on these coated samples in furnaces under controlled atmosphere for 1000 h at 650 °C. The tests were carried out using the "deposit-recoat" test method to simulate the environment that was anticipated from air-firing 20 wt.% cereal co-product mixed with a UK coal. The exposures were carried out using a deposit containing Na2SO4, K2SO4, and Fe2O3 to produce alkali-iron tri-sulfates, which had been identified as the principal cause of fireside corrosion on superheaters/reheaters in pulverized coal-fired power plants. The exposed samples were examined in an ESEM with EDX analysis to characterize the damage. Pre- and post-exposure dimensional metrologies were used to quantify the metal damage in terms of metal loss distributions. The thermally sprayed coatings suffered significant corrosion attack from a combination of aggressive combustion gases and deposit mixtures. In this study, all the four plasma-sprayed coatings studied performed better than the HVOF-sprayed coatings because of a lower level of porosity. NiCr was found to be the best performing coating material with a median metal loss of ~87 μm (HVOF sprayed) and ~13 μm (plasma sprayed). In general, the median metal damage for coatings had the following ranking (in the descending order: most to the least damage): NiCrAlY > alloy 625 > FeCrAl > NiCr.

  9. Mechanical Properties and Fracture Mechanism of WC-10Co4Cr Coating Sprayed by High Velocity Oxygen Fuel%超音速火焰喷涂 WC-10Co4Cr 涂层的力学性能及断裂机理

    Institute of Scientific and Technical Information of China (English)

    周夏凉; 陈小明; 吴燕明; 伏利; 王莉容; 马红海

    2015-01-01

    WC-10Co4Cr coating was prepared on the substrate of stainless steel by high velocity oxygen fuel (HVOF)spraying.The micro-hardness and bond strength of the coating were investigated;phase composition, section and surface morphology was studied;and the fracture mode and mechanism were analyzed as well.The results show that the average micro-hardness of the WC-10Co4Cr coating reached to 1 147.6 HV and the bond strength was 70 MPa.The tensile fracture was with typical characteristics of brittle fracture and there was no significant plastic deformation.The fracture cracks were formed under the external stress due to the pores and microcracks among particles in the coating.These cracks propagated along the interface between particle and particle and were accompanied by deflections of crack paths,then caused the fracture of the coating.%采用超音速火焰喷涂技术(HVOF)在不锈钢基体上制备了 WC-10Co4Cr 涂层,测试了涂层的显微硬度和结合强度,研究了涂层的物相组成和横截面、断裂面的形貌,分析了涂层的断裂方式和断裂机理.结果表明:WC-10Co4Cr 涂层的平均显微硬度达1147.6 HV,结合强度为70 MPa;涂层的拉伸断裂为典型的脆性断裂,没有明显的塑性变形过程;涂层中颗粒间的孔隙和微裂纹在外应力的作用下形成裂纹,裂纹沿颗粒与颗粒间的界面扩展并伴随扩展方向的偏转,最终导致涂层的断裂.

  10. Evaluation of Convergent Spray Technology(TM) Spray Process for Roof Coating Application

    Science.gov (United States)

    Scarpa, J.; Creighton, B.; Hall, T.; Hamlin, K.; Howard, T.

    1998-01-01

    The overall goal of this project was to demonstrate the feasibility of(CST) Convergent Spray Technology (Trademark) for the roofing industry. This was accomplished by producing an environmentally compliant coating utilization recycled materials, a CST(Trademark) spray process portable application cart, and hand-held applicator with a CST(Trademark) spray process nozzle. The project culminated with application of this coating to a nine hundred sixty square foot metal for NASA Marshall Space Flight Center (MSFC) in Huntsville, Alabama.

  11. Fabrication of conventional and nanostructured NiCrC coatings via HVAF technique

    Institute of Scientific and Technical Information of China (English)

    TAO Kai; ZHANG Jie; CUI Hua; ZHOU Xiang-lin; ZHANG Ji-shan

    2008-01-01

    The conventional and nanostructured NiCrC (with chemical composition of 80%NiCr-20%CrC) coatings with high quality were fabricated via high velocity air-fuel(HVAF) spraying technique. The microstructures of these coatings were characterized by means of metallographic microscopy, scanning electron microscopy, transmission electron microscopy and X-ray diffractometry. A Vickers microhardness tester was used to determine the mechanical properties of the as-sprayed coatings. The single-line approximation(SLA) method was employed to calculate the grain size and microstrain of as-sprayed nanostructured coating based on the XRD data. The results show that nanostructured NiCrC coating possesses a more uniform and denser microstructure, much higher microhardness and better fracture toughness than its conventional counterpart. Both TEM observation and calculation results based on XRD profile show that as-sprayed nanostructured NiCrC coating has a homogeneous nanocrystalline microstructure with an average grain size of 40 nm.

  12. Comparison of thermal shock behaviors between plasma-sprayed nanostructured and conventional zirconia thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    LIU Chun-bo; ZHANG Zhi-min; JIANG Xian-liang; LIU Min; ZHU Zhao-hui

    2009-01-01

    NiCoCrAlTaY bond coat was deposited on pure nickel substrate by low pressure plasma spraying(LPPS), and ZrO2-8%Y2O3 (mass fraction) nanostructured and ZrO2-7%Y2O3 (mass fraction) conventional thermal barrier coatings(TBCs) were deposited by air plasma spraying(APS). The thermal shock behaviors of the nanostructured and conventional TBCs were investigated by quenching the coating samples in cold water from 1 150, 1 200 and 1 250 ℃, respectively. Scanning electron microscopy(SEM) was used to examine the microstructures of the samples after thermal shock testing. Energy dispersive analysis of X-ray(EDAX) was used to analyze the interface diffusion behavior of the bond coat elements. X-ray diffractometry(XRD) was used to analyze the constituent phases of the samples. Experimental results indicate that the nanostructured TBC is superior to the conventional TBC in thermal shock performance. Both the nanostructured and conventional TBCs fail along the bond coat/substrate interface. The constituent phase of the as-sprayed conventional TBC is diffusionless-transformed tetragonal(t′). However, the constituent phase of the as-sprayed nanostructured TBC is cubic(c). There is a difference in the crystal size at the spalled surfaces of the nanostructured and conventional TBCs. The constituent phases of the spalled surfaces are mainly composed of Ni2.88Cr1.12 and oxides of bond coat elements.

  13. Evaluation of fatigue strength of WC cermet- and 13Cr steel-sprayed materials; WC cermet oyobi 13Cr ko yosha hifukuzai no hiro kyodo hyoka

    Energy Technology Data Exchange (ETDEWEB)

    Ogawa, T.; Tokaji, K.; Ejima, T. [Gifu University, Gifu (Japan); Kobayashi, Y.; Harada, Y. [Tocalo Co. Ltd., Kobe (Japan)

    1997-10-15

    Rotating bending fatigue tests have been conducted at room temperature in air using the specimens of medium carbon steel (S45C), low alloy steel (SCM435) and titanium alloy (Ti-6Al-4V) with HVOF sprayed coating of a cermet (WC-12%Co) and S45C with WFS sprayed coating of a 13Cr steel (SUS420 J2). The fatigue strength and fracture mechanisms were studied. The fatigue strength evaluated by nominal stress was strongly influenced by substrate materials and the thickness of sprayed coatings. Detailed observation of crack initiation on the coating surface and fracture surface revealed that microcracks initiated at the WC grain boundary coalesced, and then the crack grew rapidly in the coating. Cracks in the substrate were initiated by the stress concentration of the crack in the coating, which was modeled by finite element analysis. For the specimens tested in this study, the fatigue strength of sprayed specimens was dominated by that of sprayed coating. Thus, the fatigue strength could be evaluated uniquely by the true stress on the coating surface. 9 refs., 12 figs., 2 tabs.

  14. Microstructure evolution of cold-sprayed coating during deposition and through post-spraying heat treatment

    Institute of Scientific and Technical Information of China (English)

    LI Chang-jiu; LI Wen-ya

    2004-01-01

    The microstructural features of cold-sprayed coatings were investigated using Cu, Ti and Zn feedstocks by optical microscopy, scanning electron microscopy and transmission electron microscopy to reveal the microstructure evolution mechanisms in cold spray. Four typical effects including tamping, refinement, impact-induced fusion and annealing were examined on microstrueture. It is found that the microstructure of cold spray coating is remarkably influenced by spray materials. Ti coatings consist of evident porous layer and Cu coatings present a limited porous layer only near the surface. It is clear that the successive tamping effect and dynamic refinement of grains significantly influence the microstructure evolution of cold-sprayed coating. The tamping effect leads to the densification of porous coating layer gradually and the refinement effect leads to the formation of fine microstructure. It is considered that the large difference in the formation of porous layer is attributed to the dynamic impact pressure and hardenability of materials. It is also found that the impact-induced fusion during deposition of Zn coating can also modify the interfacial microstructure between particles in cold spray coating. Moreover, the nanocrystalline phase can be formed at the interfaces among particles resulting from the localized melting of the interfaces and tamping effect. Furthermore, the annealing treatment can modify the microstructure and property of a cold-sprayed coating.

  15. Interdiffusion between Co3O4 coating and the oxide scale of Fe-22Cr alloy

    DEFF Research Database (Denmark)

    Hansson, Anette Nørgaard; Friehling, Peter B.; Linderoth, Søren

    2002-01-01

    In solid oxide fuels cell stacks, the Fe-Cr interconnector plates and their oxidation scale formed during operation must have sufficiently high electrical conductivity at the operating temperature. It is anticipated that this can be achieved by reaction-diffusion between Co3O4 and the chromia scale...... on Fe-Cr alloys. Coatings of Co3O4 were deposited on a Fe-22Cr alloy by plasma spraying and spray-painting. As-deposited samples were oxidised in air containing 1% H2O at 900C for various exposure time. During exposure the Fe-22Cr alloy forms an oxide scale, which reacts with the coating. The effects...... of inter-diffusion between the oxide scale and the Co3O4 coating were investigated with X-ray diffraction, scanning electron microscopy and energy-dispersive spectroscopy. The results obtained are discussed in relation to a calculated Cr-Co-oxide phase diagrams....

  16. Plasma sprayed and electrospark deposited zirconium metal diffusion barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Hollis, Kendall J [Los Alamos National Laboratory; Pena, Maria I [Los Alamos National Laboratory

    2010-01-01

    Zirconium metal coatings applied by plasma spraying and electrospark deposition (ESD) have been investigated for use as diffusion barrier coatings on low enrichment uranium fuel for research nuclear reactors. The coatings have been applied to both stainless steel as a surrogate and to simulated nuclear fuel uranium-molybdenum alloy substrates. Deposition parameter development accompanied by coating characterization has been performed. The structure of the plasma sprayed coating was shown to vary with transferred arc current during deposition. The structure of ESD coatings was shown to vary with the capacitance of the deposition equipment.

  17. Microstructure of Ni-Based Self-Fluxing Alloy Sprayed Coating

    Institute of Scientific and Technical Information of China (English)

    WANG Jin-hua; Milan Friesel; Magnus Willander; Richard Warren

    2005-01-01

    The microstructure of Ni-based self-fluxing alloy thermal sprayed coating was investigated by microanal ysis methods.The sprayed coating was produced by the oxygen-acetylene gas flame spraying Ni-16.9Cr-3.5B4.5Si-4.6Fe-0.83C system alloy powder onto a common steel substrate.Different phases can be recognized from the morphology in the metallographic images and SEM images of compounds of high magnification.The TEM images of the (Cr,Fe,Ni) superlattice phase particles can be obtained in dark field,and the particle size is between 20 nm and 60 nm.The electron diffraction patterns of the superlattice phase and Ni-based solid solution phase can be found,as analyzed by the EDAX spectra chemical composition analysis method.

  18. Influence of Different Interfacial Conditions on Bond Strength of Plasma - Sprayed Tungsten Coatings

    Energy Technology Data Exchange (ETDEWEB)

    Song, S.X. [Research Center on Fusion Materials (RCFM), University of Science and Technology Beijing (USTB), 10008 3 Beijing (China); Zhou, Z.; Ge, C. [Lab. of Special Ceramic and P/M, University of Science and Technology, 100083 Beijing (China)

    2007-07-01

    Full text of publication follows: How to improve the interfacial performance and obtain high bond strength is a common problem in plasma-sprayed W coatings onto Cu substrates as plasma-facing components (PFC). This phenomenon results from the high interfacial residual stress state created by different thermal expansion coefficients, melting points and elastic modulus between W and Cu during the spraying processes. In this paper, tungsten coatings were deposited onto the oxygen free copper by plasma spraying. Various interlayers were designed to relieve the residual stress between W coatings and Cu substrates. These interlayers included NiCrAl, NiAl, NiCrAlY, W(50 %) Cu (50%) and functionally graded bonding coatings NiCrAl/AlCu, W/Cu and so on. SEM, EDS and XRD were employed to investigate the microstructure, photographs and compositions of the interfacial layers. Finite element coupled heat transfer and elastic-plastic thermal stress analysis using finite element analysis (FEA) were utilized to simulate the residual stress generation during the depositing process. The residual stresses were also calculated using this method to explain the variations of the interfacial characteristics with the various interlayers. In addition, tensile tests in conjunction with finite element analysis (FEA) were also performed to better understand the influence of both material selection and component distribution on bonding strength between the coatings and the substrates. As a result, a predicted coating system with the possibility of reducing the residual stress level was also proposed. (authors)

  19. Development of a CuNiCrAl Bond Coat for Thermal Barrier Coatings in Rocket Combustion Chambers

    Science.gov (United States)

    Fiedler, Torben; Rösler, Joachim; Bäker, Martin

    2015-12-01

    The lifetime of rocket combustion chambers can be increased by applying thermal barrier coatings. The standard coating systems usually used in gas turbines or aero engines will fail at the bond coat/substrate interface due to the chemical difference as well as the different thermal expansion between the copper liner and the applied NiCrAlY bond coat. A new bond coat alloy for rocket engine applications was designed previously with a chemical composition and coefficient of thermal expansion more similar to the copper substrate. Since a comparable material has not been applied by thermal spraying before, coating tests have to be carried out. In this work, the new Ni-30%Cu-6%Al-5%Cr bond coat alloy is applied via high velocity oxygen fuel spraying. In a first step, the influence of different coating parameters on, e.g., porosity, amount of unmolten particles, and coating roughness is investigated and a suitable parameter set for further studies is chosen. In a second step, copper substrates are coated with the chosen parameters to test the feasibility of the process. The high-temperature behavior and adhesion is tested with laser cycling experiments. The new coatings showed good adhesion even at temperatures beyond the maximum test temperatures of the NiCrAlY bond coat in previous studies.

  20. Microstructures and Tribological Properties of Fe-Based Amorphous Metallic Coatings Deposited via Supersonic Plasma Spraying

    Science.gov (United States)

    Zhou, Yang-yang; Ma, Guo-zheng; Wang, Hai-dou; Li, Guo-lu; Chen, Shu-ying; Fu, Bin-guo

    2017-08-01

    The effects of the Ar flow rate and spraying power of a supersonic plasma spraying process on the microstructures and amorphous phase contents of Fe48Cr15Mo14C15B6Y2 amorphous coatings were systematically investigated. The tribological properties of the coatings were evaluated in pin-on-disk mode using a sliding tribometer. The results show that the amorphous phase content and microhardness initially increase with the Ar flow rate and then gradually decrease. However, the amorphous phase content and microhardness increase with the power. In particular, the amorphous phase content of the coating reaches 96.78% with a spraying power of 62 kW and a 110 L min-1 Ar flow rate. Tribological testing demonstrates that the coatings exhibit similar steady-state coefficients of friction (0.75-0.82) with a total test time of 20 min and an applied load of 20 N. However, the wear rates vary with the spraying parameters. In particular, the relative wear rate of the coating can be enhanced up to sixfold under optimal spraying conditions, resulting in excellent wear resistance. Detailed analysis of the coating wear surfaces indicates that the dominant wear mechanisms are abrasive and oxidative wear. Moreover, delamination may occur during the wear process.

  1. Investigation about the Chrome Steel Wire Arc Spray Process and the Resulting Coating Properties

    Science.gov (United States)

    Wilden, J.; Bergmann, J. P.; Jahn, S.; Knapp, S.; van Rodijnen, F.; Fischer, G.

    2007-12-01

    Nowadays, wire-arc spraying of chromium steel has gained an important market share for corrosion and wear protection applications. However, detailed studies are the basis for further process optimization. In order to optimize the process parameters and to evaluate the effects of the spray parameters DoE-based experiments had been carried out with high-speed camera shoots. In this article, the effects of spray current, voltage, and atomizing gas pressure on the particle jet properties, mean particle velocity and mean particle temperature and plume width on X46Cr13 wire are presented using an online process monitoring device. Moreover, the properties of the coatings concerning the morphology, composition and phase formation were subject of the investigations using SEM, EDX, and XRD-analysis. These deep investigations allow a defined verification of the influence of process parameters on spray plume and coating properties and are the basis for further process optimization.

  2. Microstructure and Oxidation Resistance of Laser Remelted Plasma Sprayed Nicraly Coating

    Directory of Open Access Journals (Sweden)

    Niemiec D.

    2016-06-01

    Full Text Available The article presents results of research relating to the impact of laser treatment done to the surface of plasma sprayed coatings NiCrAlY. Analysis consisted microstructure and oxidation resistance of coatings subjected to two different laser melting surfaces. The test were performed at a temperature 1000°C the samples were removed from the furnace after 25, 300, 500, 750 and 1000 hours. The investigations range included analysis of top surface of coatings by XRD characterization oxides formed types and microscopic investigations of coatings morphology

  3. Study of Oxidation Behaviour of Bond Coating Nanocomposites Ni-20Cr-6Al Powder Synthesized by Mechanical Alloying

    OpenAIRE

    Akbar Salarvand; Vahid Shafi pour

    2011-01-01

    In this study, nano crystalline Ni-20Cr-6Al composite powder was produced using a high energy planetary ball milling and a two-stage process. Then the oxidation behavior of coating of that superalloy at different temperatures considered. Nanostructured Ni-20Cr-6Al coating was deposited by cold spray for application as a bond coat to thermal barrier coating on industrial gas turbine components. The paper samples synthesized were characterized by scanning electron microscopy (SEM) and transmiss...

  4. Photochromic lens mirror-coated with Cr

    Science.gov (United States)

    Shin, Sungho; Lee, Myeongkyu

    2007-11-01

    We have designed and fabricated mirror-coated photochromic lenses for use in sunglasses. These lenses consisted of a Cr thin film sandwiched between two SiO2 layers on the front surface and an anti-reflection (AR) coating on the backside. The SiO2 films above and below the Cr layer were introduced as the protection and buffer layers, respectively. The AR coating was to suppress back-reflection from the lens surface. Deposition of all coating layers were carried out by an e-beam evaporator under Ar atmosphere at P = 10-5 Torr and T = 70 °C. As expected, the overall transmittance decreased with increasing Cr thickness. For a Cr layer of 5 nm thickness, it changed from about 45% in the bleached state down to 25% after exposure to sunlight. This is consistent with the transmission range typically required for sunglasses.

  5. Plasma spray for forming nanostructured thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    LIN; Feng; JIANG; Xian-liang; YU; Yue-guang; ZENG; Ke-li; REN; Xian-jing

    2005-01-01

    Nanocrystalline powders of yttrium partially stabilized zirconia (YPSZ) are reprocessed into agglomerated feedstocks for plasma spraying thermal barrier coatings (TBCs), using the methods of ball milling, slurry dispersion, spray drying, and heat treatment. Atmospheric plasma is used to spray the agglomerated nanocrystalline particle feedstocks and coatings were deposited on the substrate of Ni-based superalloy. Scanning electron microscopy (SEM) is used to examine the morphology and cross-section of the agglomerated feedstocks and the free-section and cross-section of the nanostructured TBCs. Experimental results show that the agglomerated nanocrystalline particles are spherical and dense. Unlike conventional plasma-sprayed coatings, the micron/nano/micron sandwich structure can be found in the nanostructured YPSZ coatings deposited by atmospheric plasma spraying.

  6. Tribological properties of high velocity arc sprayed Fe-Al based composite coatings at elevated temperature

    Institute of Scientific and Technical Information of China (English)

    ZHANG Wei; ZHANG Shu; XU Wei-pu; ZU Zi-xin; XU Bin-shi

    2004-01-01

    Fe-Al based intermetallic composite coatings were in-situ synthesized using Fe-Al/Cr3C2 or Fe-Al/WC cored wires and high velocity are spraying (HVAS) technology. The tribological properties of the Fe-Al based intermetallic composite coatings were investigated using a ball-on-disc tribotester from room temperature to 650 ℃. The results show that the coatings have relatively high bond strength and micro-hardness. The tribological properties of Fe-Al/Cr3C2 and Fe-Al/WC composite coatings were further analyzed and compared. Low and stable wear rates of the Fe-Al based intermetallic composite coatings were indicated from room temperature to 650 ℃. The excellent wear resistance of the composite coatings in high temperature was discussed.

  7. High Temperature Behavior of Cr3C2-NiCr Coatings in the Actual Coal-Fired Boiler Environment

    Science.gov (United States)

    Bhatia, Rakesh; Sidhu, Hazoor Singh; Sidhu, Buta Singh

    2015-03-01

    Erosion-corrosion is a serious problem observed in steam-powered electricity generation plants, and industrial waste incinerators. In the present study, four compositions of Cr3C2-(Ni-20Cr) alloy coating powder were deposited by high-velocity oxy-fuel spray technique on T-91 boiler tube steel. The cyclic studies were performed in a coal-fired boiler at 1123 K ± 10 K (850 °C ± 10 °C). X-ray diffraction, scanning electron microscopy/energy dispersive X-ray analysis and elemental mapping analysis techniques were used to analyze the corrosion products. All the coatings deposited on T-91 boiler tube steel imparted hot corrosion resistance. The 65 pctCr3C2 -35 pct (Ni-20Cr)-coated T-91 steel sample performed better than all other coated samples in the given environment.

  8. Fabrication of Nanosized Lanthanum Zirconate Powder and Deposition of Thermal Barrier Coating by Plasma Spray Process

    Science.gov (United States)

    Mishra, S. K.; Jagdeesh, N.; Pathak, L. C.

    2016-07-01

    The present manuscript discusses our findings on fabrication of nanosized lanthanum zirconate powder for thermal barrier coating application and its coating by plasma spray on nickel-based superalloy substrate. Single-phase La2Zr2O7 coating of thickness of the order of 45 µm on the Ni-Cr-Al bond coat coated Ni-based superalloy substrate was deposited by plasma spray process. The layers at the interface did not show spallation and inter diffusion was very less. The microstructure, interface, porosity, and mechanical properties of different layers are investigated. The lanthanum zirconate hardness and modulus were 10.5 and 277 GPa, respectively. The load depth curve for lanthanum zirconate showed good elastic recovery around 74%.

  9. Duplex Al-based thermal spray coatings for corrosion protection in high temperature refinery applications

    Directory of Open Access Journals (Sweden)

    Rocha Adriana da Cunha

    2004-01-01

    Full Text Available The application of thermal spray coatings has been effective in preventing corrosion of steel and iron products. It has been used in a wide range of applications spreading from the petroleum to the food industry. In this work, the performance and effectiveness of a two-layered aluminum-based thermal spray coating applied to an ASTM A387 G11 steel was evaluated. The coating structure was comprised of an inner Al-Fe-Cr layer and an outer layer of aluminum. Coated samples were tested in the reactor zone of a fluid catalytic cracking unit (FCCU of a petrochemical plant for 2.5 years. The reactor zone temperature was about 793 K (520 °C and the environment was a mixed gas containing sulfur, oxygen and carbon. Laboratory-scale tests were also conducted on the coated samples in order to gain a better understanding of the corrosive effect of the gaseous species present in the FCCU atmosphere. Porosity present in the thermal spray coatings allowed the penetration of the atmosphere corrodents, which instigated intergranular corrosion of the steel substrate. The presence of an inner Al-Fe-Cr layer did not prevent coating spallation, which further contributed to the internal corrosion process.

  10. Metallurgical characterization and determination of residual stresses of coatings formed by thermal spraying

    Science.gov (United States)

    Laribi, M.; Mesrati, N.; Vannes, A. B.; Treheux, D.

    2003-06-01

    This work presents an experimental determination of residual stresses in 35CrMo4 (Euronorm) low alloyed steel substrates with thermally sprayed coatings. Two different materials were separately deposited. The first one consisted of a blend of two superalloys: Cr-Ni steel and Cr-Mn steel, designated 55E and 65E, respectively. The second material was molybdenum. In a first part, basic characteristics of the deposited layers (metallographic analysis, hardness, and adhesion) are presented. In a second part, the determination of the residual stresses, in both substrate and thermal sprayed layers is performed using an extensometric method in combination with a simultaneous progressive electrolytic polishing. The influence of a nickel-aluminum (80:20%) bond-coat and/or a post-annealing at 850 °C in air for 1 h is studied.

  11. Titanium carbonitride thick coating prepared by plasma spray synthesis and its tribological properties

    Institute of Scientific and Technical Information of China (English)

    ZHU Lin; HE JiNing; YAN DianRan; XIAO LiSong; DONG YanChun; XUE DingChuan; MENG DeLiang

    2007-01-01

    TiCN coating,owing to its superior wear-resistance,has been frequently applied in many fields. TiCN thick coating was first prepared by reactive plasma spraying. The phase composition,microstructure and tribological properties of the TiCN coating were investigated in this research. Experimental results show that the microstructure of the TiCN coating was quite dense,and there was also a little amount of titanium oxides within the coating. By XPS analysis,Ti-C and Ti-N bonds were detected in the coating. The TiCN coating exhibited superior wear-resistance. The failure mechanism was attributed to the adhesive wear,the grinding of TiCN hard-grain,as well as the coating failure by oxidation. There were more Fe,Cr,O,etc. in the failure zone,suggesting that the corrosion propagated gradually from surface to interior.

  12. Nanostructured yttria stabilized zirconia coatings deposited by air plasma spraying

    Institute of Scientific and Technical Information of China (English)

    ZHOU Hong; LI Fei; HE Bo; WANG Jun; SUN Bao-de

    2007-01-01

    Nanostructured yttria partially stabilized zirconia coatings were deposited by air plasma spraying with reconstituted nanosized powder. The microstructures and phase compositions of the powder and the as-sprayed nanostructured coatings were characterized by transmission electron microscopy(TEM), scanning electron microscopy(SEM) and X-ray diffraction(XRD). The results demonstrate that the microstructure of as-sprayed nanostructured zirconia coating exhibits a unique tri-modal distribution including the initial nanostructure of the powder, equiaxed grains and columnar grains. Air plasma sprayed nanostructured zirconia coatings consist of only the nontransformable tetragonal phase, though the reconstituted nanostructured powder shows the presence of the monoclinic, the tetragonal and the cubic phases. The mean grain size of the coating is about 42 nm.

  13. Suspension plasma sprayed composite coating using amorphous powder feedstock

    Energy Technology Data Exchange (ETDEWEB)

    Chen Dianying [Department of Chemical, Materials and Biomolecular Engineering, Institute of Materials Science, University of Connecticut, 97 N Eagleville Rd U-3136, Storrs, CT 06269 (United States)], E-mail: chendy@ims.uconn.edu; Jordan, Eric H. [Department of Mechanical Engineering, University of Connecticut, Storrs, CT 06269 (United States); Gell, Maurice [Department of Chemical, Materials and Biomolecular Engineering, Institute of Materials Science, University of Connecticut, 97 N Eagleville Rd U-3136, Storrs, CT 06269 (United States)

    2009-03-15

    Al{sub 2}O{sub 3}-ZrO{sub 2} composite coatings were deposited by the suspension plasma spray process using molecularly mixed amorphous powders. X-ray diffraction (XRD) analysis shows that the as-sprayed coating is composed of {alpha}-Al{sub 2}O{sub 3} and tetragonal ZrO{sub 2} phases with grain sizes of 26 nm and 18 nm, respectively. The as-sprayed coating has 93% density with a hardness of 9.9 GPa. Heat treatment of the as-sprayed coating reveals that the Al{sub 2}O{sub 3} and ZrO{sub 2} phases are homogeneously distributed in the composite coating.

  14. Microstructural Characteristics and Tribological Behavior of HVOF-Sprayed Novel Fe-Based Alloy Coatings

    Directory of Open Access Journals (Sweden)

    Andrea Milanti

    2014-01-01

    Full Text Available Thermally-sprayed Fe-based coatings have shown their potential for use in wear applications due to their good tribological properties. In addition, these kinds of coatings have other advantages, e.g., cost efficiency and positive environmental aspects. In this study, the microstructural details and tribological performances of Fe-based coatings (Fe-Cr-Ni-B-C and Fe-Cr-Ni-B-Mo-C manufactured by High Velocity Oxygen Fuel (HVOF thermal spray process are evaluated. Traditional Ni-based (Ni-Cr-Fe-Si-B-C and hard-metal (WC-CoCr coatings were chosen as references. Microstructural investigation (field-emission scanning electron microscope FESEM and X-Ray diffractometry XRD reveals a high density and low oxide content for HVOF Fe-based coatings. Particle melting and rapid solidification resulted in a metastable austenitic phase with precipitates of mixed carbides and borides of chromium and iron which lead to remarkably high nanohardness. Tribological performances were evaluated by means of the ball on-disk dry sliding wear test, the rubber-wheel dry particle abrasion test, and the cavitation erosion wear test. A higher wear resistance validates Fe-based coatings as a future alternative to the more expensive and less environmentally friendly Ni-based alloys.

  15. Nondestructive inspection of plasma-sprayed metallic coatings for coal conversion equipment

    Energy Technology Data Exchange (ETDEWEB)

    Scott, G.W.; Snyder, S.D.; Simpson, W.A. Jr.

    1979-12-01

    This report describes the results of a project to develop nondestructive inspection techniques for metallic wear- and process-resistant coatings used in coal system components. Physical properties, especially porosity, and the nominal 0.25 mm (0.010 in.) thickness complicate the inspection of these coatings. The class of coatings selected for laboratory evaluation were CoCrAlY (cobalt-chromium-aluminum-yttrium) types; the specific material used was a Union Carbide spray powder, UCAR LCO-7, which is Co-22.8% Cr-12.9% Al-0.6% Y, sprayed onto alloy 800 substrates. The desired inspection techniques were to: (1) detect cracks or holes in the coating; (2) measure the coating thickness from the coated side; and (3) detect lamellar flaws or separations within the coating layer or between the coating and the substrate. Surface methods (such as liquid penetrant), eddy currents, and radiography were investigated for crack and hole detection; eddy currents, x-ray fluorescence, and ultrasonics were investigated for thickness measurement; and ultrasonics and infrared thermography were investigated for lamellar flaw detection. In general, we determined that significant development effort was required to adapt even the more common and highly developed techniques to the coating inspection problems. Significant progress was made in a number of the investigations undertaken, but financial restraints prevented completion of the planned work.

  16. Superhydrophobic Ceramic Coatings by Solution Precursor Plasma Spray

    Science.gov (United States)

    Cai, Yuxuan

    Superhydrophobic surfaces exhibit superior water repellent properties, and they have remarkable potential to improve current energy infrastructure. Substantial research has been performed on the production of superhydrophobic coatings. However, superhydrophobic coatings have not yet been adopted in many industries where potential applications exist due to the limited durability of the coating materials and the complex and costly fabrication processes. Here presented a novel coating technique to manufacture ceramic superhydrophobic coatings rapidly and economically. A rare earth oxide (REO) was selected as the coating material due to its hydrophobic nature and strong mechanical properties, and deposited on stainless steel substrates by solution precursor plasma spray (SPPS). The as-sprayed coating demonstrated a hierarchically structured coating topography, which closely resembles superhydrophobic surfaces in nature. Compared to smooth REO surfaces, the SPPS superhydrophobic coating improved the water contact angle by as much as 65° after vacuum treatment at 1 Pa for 48 hours.

  17. Corrosion behavior of magnetic ferrite coating prepared by plasma spraying

    Energy Technology Data Exchange (ETDEWEB)

    Liu, Yi; Wei, Shicheng, E-mail: wsc33333@163.com; Tong, Hui; Tian, Haoliang; Liu, Ming; Xu, Binshi

    2014-12-15

    Graphical abstract: The saturation magnetization (M{sub s}) of the ferrite coating is 34.417 emu/g while the M{sub s} value of the ferrite powder is 71.916 emu/g. It can be seen that plasma spray process causes deterioration of the room temperature soft magnetic properties. - Highlights: • Spinel ferrite coatings have been prepared by plasma spraying. • The coating consists of nanocrystalline grains. • The saturation magnetization of the ferrite coating is 34.417 emu/g. • Corrosion behavior of the ferrite coating was examined in NaCl solution. - Abstract: In this study, spray dried spinel ferrite powders were deposited on the surface of mild steel substrate through plasma spraying. The structure and morphological studies on the ferrite coatings were carried out using X-ray diffraction, scanning electron microscope and Raman spectroscopy. It was showed that spray dried process was an effective method to prepare thermal spraying powders. The coating showed spinel structure with a second phase of LaFeO{sub 3}. The magnetic property of the ferrite samples were measured by vibrating sample magnetometer. The saturation magnetization (M{sub s}) of the ferrite coating was 34.417 emu/g. The corrosion behavior of coating samples was examined by electrochemical impedance spectroscopy. EIS diagrams showed three corrosion processes as the coating immersed in 3.5 wt.% NaCl solution. The results suggested that plasma spraying was a promising technology for the production of magnetic ferrite coatings.

  18. Porosity and wear resistance of flame sprayed tungsten carbide coatings

    Science.gov (United States)

    Winarto, Winarto; Sofyan, Nofrijon; Rooscote, Didi

    2017-06-01

    Thermal-sprayed coatings offer practical and economical solutions for corrosion and wear protection of components or tools. To improve the coating properties, heat treatment such as preheat is applied. The selection of coating and substrate materials is a key factor in improving the quality of the coating morphology after the heat treatment. This paper presents the experimental results regarding the effect of preheat temperatures, i.e. 200°C, 300°C and 400°C, on porosity and wear resistance of tungsten carbide (WC) coating sprayed by flame thermal coating. The powders and coatings morphology were analyzed by a Field Emission Scanning Electron Microscope equipped with Energy Dispersive Spectrometry (FE-SEM/EDS), whereas the phase identification was performed by X-Ray diffraction technique (XRD). In order to evaluate the quality of the flame spray obtained coatings, the porosity, micro-hardness and wear rate of the specimens was determined. The results showed that WC coating gives a higher surface hardness from 1391 HVN up to 1541 HVN compared to that of the non-coating. Moreover, the wear rate increased from 0.072 mm3/min. to 0.082 mm3/min. when preheat temperature was increased. Preheat on H13 steel substrate can reduce the percentage of porosity level from 10.24 % to 3.94% on the thermal spray coatings.

  19. The low cycle fatigue behavior of a plasma-sprayed coating material

    Science.gov (United States)

    Gayda, J.; Gabb, T. P.; Miner, R. V., Jr.

    1986-01-01

    Single crystal nickel-base superalloys employed in turbine blade applications are often used with a plasma spray coating for oxidation and hot corrosion resistance. These coatings may also affect fatigue life of the superalloy substrate. As part of a large program to understand the fatigue behavior of coated single crystals, fully reversed, total strain controlled fatigue tests were run on a free standing NiCoCrAlY coating alloy, PWA 276, at 0.1 Hz. Fatigue tests were conducted at 650 C, where the NiCoCrAlY alloy has modest ductility, and at 1050 C, where it is extremely ductile, showing tensile elongation in excess of 100 percent. At the lower test temperature, deformation induced disordering softened the NiCoCrAlY alloy, while at the higher test temperature cyclic hardening was observed which was linked to gradual coarsening of the two phase microstructure. Fatigue life of the NiCoCrAlY alloy was significantly longer at the higher temperature. Further, the life of the NiCoCrAlY alloy exceeds that of coated, /001/-oriented PWA 1480 single crystals at 1050 C, but at 650 C the life of the coated crystal is greater than that of the NiCoCrAlY alloy on a total strain basis.

  20. Low cycle fatigue behaviour of a plasma-sprayed coating material

    Science.gov (United States)

    Gayda, J.; Gabb, T. P.; Miner, R. V.

    1986-01-01

    Single crystal nickel-base superalloys employed in turbine blade applications are often used with a plasma spray coating for oxidation and hot corrosion resistance. These coatings may also affect fatigue life of the superalloy substrate. As part of a large program to understand the fatigue behavior of coated single crystals, fully reversed, total strain controlled fatigue tests were run on a free standing NiCoCrAlY coating alloy, PWA 276, at 0.1 Hz. Fatigue tests were conducted at 650 C, where the NiCoCrAlY alloy has modest ductility, and at 1050 C, where it is extremely ductile, showing tensile elongation in excess of 100 percent. At the lower test temperature, deformation induced disordering softened the NiCoCrAlY alloy, while at the higher test temperature cyclic hardening was observed which was linked to gradual coarsening of the two phase microstructure. Fatigue life of the NiCoCrAlY alloy was significantly longer at the higher temperature. Further, the life of the NiCoCrAlY alloy exceeds that of coated, /001/-oriented PWA 1480 single crystals at 1050 C but at 650 C the life of the coated crystal is greater than that of the NiCoCrAlY alloy on a total strain basis.

  1. Preparation and Properties of High Hardness and Oxidation Resisting Coating Using Electric Arc Spray

    Institute of Scientific and Technical Information of China (English)

    LIZhuo-xin; CUILi; WANGJiang-ping; TANGChun-tian

    2004-01-01

    A coating with high hardness, wear and oxidation resistance was prepared by electric arc spray. The hardness, bonding strength, abrasive wear and values of porosity and oxidation resistance of the coating were investigated. The microstructures and function of Cr3C2 of the coating were analyzed. The results showed surface Rockness Hardness HR30 reached 72.5 and average bond strength reached 49.1Mpa. Also porosity value was less than 2%. In addition, it was found from the comparison between the coating and 45CT coating that, oxidation resistance of the coating was less than that of 45CT, but the abrasive wear of the coating was obvious better than that of 45CT.

  2. Preparation and Properties of High Hardness and Oxidation Resisting Coating Using Electric Arc Spray

    Institute of Scientific and Technical Information of China (English)

    LI Zhuo-xin; CUI Li; WANG Jiang-ping; TANG Chun-tian

    2004-01-01

    A coating with high hardness, wear and oxidation resistance was prepared by electric arc spray. The hardness,bonding strength, abrasive wear and values of porosity and oxidation resistance of the coating were investigated. The microstructures and function of Cr3C2 of the coating were analyzed. The results showed surface Rockness Hardness HR30 reached 72.5 and average bond strength reached 49.1Mpa. Also porosity value was less than 2%. In addition, it was found from the comparison between the coating and 45CT coating that, oxidation resistance of the coating was less than that of 45CT, but the abrasive wear of the coating was obvious better than that of 45CT.

  3. POROSITY EVALUATION OF FLAME-SPRAYED AND HEAT-TREATED NICKEL-BASED COATINGS USING IMAGE ANALYSIS

    Directory of Open Access Journals (Sweden)

    Zoran Bergant

    2011-03-01

    Full Text Available Flame sprayed coatings are susceptible to the formation of inter-connected elongated porosity due to the lack of fusion between sprayed particles or the expansion of gases generated during the spraying process. The partial remelting of self-fluxing Ni-Cr-B-Si coating after spraying is an efficient method to reduce porosity and to improve coating microstructural and mechanical properties. The paper describes the image preprocessing procedure for noise removal which separates the pores from the background and the noise. The optimal temperature and time of a furnace heat treatment of Ni-Cr-B-Si coated specimens was determined by using a three-level factorial experiment. The purpose was to obtain the lowest possible porosity. Equivalent diameter, elongation, and major axis angle were analyzed and compared using probability density functions. The experiment shows zero-percent porosity cannot be obtained with a partial remelting of flame-sprayed Ni-Cr-B-Si coatings; however, porosity can be greatly reduced. This method of coating post-processing not only favours pore size and shape but also eliminates the undesired network of interconnected elongated pores.

  4. Research into Thermal Sprayed Coatings with Ultrasonic Methods

    Directory of Open Access Journals (Sweden)

    Justinas Gargasas

    2012-01-01

    Full Text Available Research on thermal sprayed coatings with ultrasonic methods is the main object of this thesis. Metal surface coating was applied to modify its mechanical and physical-chemical properties and resistance to external impact and improve aesthetics. Spraying was carried out by scanning the rotating sample of 30 cm/s speed. Surface microstructure, ultrasonic thickness, porosity, micro hardness and surface modulus tests performed. Conclusions were formulated.Article in Lithuanian

  5. Microstructure and Properties of Plasma Spraying Boron Carbide Coating

    Institute of Scientific and Technical Information of China (English)

    2000-01-01

    Microstructure of plasma spray boron carbide coating was studied by SEM and TEM. Its physical,mechanical and electrical properties were measured. The results showed that high microhardness,modulus and Iow porosity of B4C coating were manufactured by plasma spray. It was lamellar packing and dense. The B4C coating examined here contained two principal structures and two impurity phase besides major phase. The relatively small value of Young′s modulus, comparing with that of the bulk materials, is explained by porosity. The Fe impurity phase could account for the relatively high electrical conductivity of boron carbide coating by comparing with the general boron carbide materials.

  6. EVALUATION OF CONVERGENT SPRAY TECHNOLOGYTM SPRAY PROCESS FOR ROOF COATING APPLICATION

    Science.gov (United States)

    The overall goal of this project was to demonstrate the feasibility of Convergent Spray TechnologyTM for the roofing industry. This was accomplished by producing an environmentally compliant coating utilizing recycled materials, a CSTTM spray process portable application cart, a...

  7. STUDY ON THE EROSION-CORROSION BEHAVIOR OF STEELS AND THERMAL SPRAYED COATINGS

    Institute of Scientific and Technical Information of China (English)

    ChenHuahui; ZhaoHuiyou; ShooHesheng; ZhaoShanzhon

    1996-01-01

    16Mn steel, 1Cr18Ni9 stainless steel, thermal sprayed Al2O3-TiO2 ceramic coating and nylonl010-5%Al2O3 coating were tested with an erosion-corrosion tester.The effects of pH values and slurry velocities on the erosion-corrosion behavior of the materials tested were determined. The erosion-corrosion behavior of the materials tested changes with pH values and presents different change tendencies. The erosion-corrosion rates of the materials are increased with slurry velocities. The erosion-corrosion mechanisms for the steels and the coatings are considerably different.

  8. Surface Microstructure of Nanoaluminized CoCrAlY Coating Irradiated by HCPEB

    Directory of Open Access Journals (Sweden)

    Zhiyong Han

    2016-01-01

    Full Text Available A thermal sprayed CoCrAlY coating was prepared by air plasma spray on the surface of Ni-based superalloy GH4169; then, a nanoscale aluminum film was deposited with electron beam vacuum deposition on it. The coatings irradiated by high-current pulsed electron beam were investigated. After HCPEB treatment, the Al film was remelted into the bond coat. XRD result shows that Al and Al2O3 phase were recorded in the irradiated and aluminized coatings, while Co-based oxides which originally existed in the initial samples disappeared. Microstructure observations reveal that the original coating with porosity, cavities, and inclusions was significantly changed after HCPEB treatment as compact appearance of interconnected bulged nodules. Moreover, the grains on the irradiated coating were very refined and homogeneously dispersed on the surface, which could effectively inhibit the corrosive gases and improve the coating oxidation resistance.

  9. Microstructure and Wear Behavior of FeBSiNbCr Metallic Glass Coatings

    Institute of Scientific and Technical Information of China (English)

    Jiangbo Cheng; Xiubing Liang; Binshi Xu; Yixiong Wu

    2009-01-01

    In this paper, FeBSiNbCr metallic glass coatings were prepared onto AISI 1045 steel substrate by using wire arc spraying process. The phase and structure of the coating were characterized by transmission electron microscopy (TEM), X-ray diffraction (XRD) and scanning election microscopy (SEM) equipped with energy dispersive X-ray analysis (EDX). The microstructure of the coating consists of full amorphous phase. The coating has high hardness and low porosity. Full density and little oxides are detected in the coating. The mechanical properties, especially wear resistance, were investigated. The relationship between wear behavior and structure of the coatings were analyzed in detail. The main failure mechanism of the metallic glass coating is brittle breaking and fracture. The results indicate that FeBSiNbCr metallic glass coating has excellent resistance to abrasive wear.

  10. Corrosion Resistance of NiCrAl Coatings in the Salt Spray Tests%盐雾条件下NiCrAl涂层的耐腐蚀性研究

    Institute of Scientific and Technical Information of China (English)

    李垚; 马彬; 赵九蓬; 魏庆元; 苏柯

    2010-01-01

    采用大气等离子喷涂工艺在Ni基高温合金上制备NiCrAl涂层,并研究了该涂层在盐雾腐蚀和氧化条件下的耐腐蚀性能.通过对NiCfAl涂层盐雾腐蚀前后的极化曲线分析,可知NiCrAl涂层盐雾腐蚀后的腐蚀电位变得更负,腐蚀电流密度变得更大,说明经过盐雾腐蚀后的NiCrAl涂层的耐腐蚀性明显下降.由SEM观察可知,NiCrAl涂层经过盐雾腐蚀后表面和内部都出现了大量的裂纹,组织变得疏松,遭到严重腐蚀,涂层失去保护能力.经EDX分析可知,腐蚀产物的化学通式为MexOyClz.经过预氧化的NiCrAl涂层由于形成了θ-Al2O3膜,耐腐蚀性能增强.

  11. Influence of a powder feed rate on the properties of the plasma sprayed chromium carbide- 25% nickel chromium coating

    Directory of Open Access Journals (Sweden)

    Mihailo R. Mrdak

    2014-04-01

    Full Text Available Normal 0 false false false MicrosoftInternetExplorer4 The plasma spray process is a leading technology of powder depositing in the production of coatings widely used in the aerospace industry for the protection of new parts and for the repair of worn ones. Cermet 75Cr3C2 - 25Ni(Cr coatings based on Cr3C2 carbides are widely used to protect parts as they retain high values of hardness, strength and resistance to wear up to a temperature of 850°C. This paper discusses the influence of the parameters of the plasma spray deposition of 75Cr3C2 - 25Ni(Cr powder on the structure and mechanical properties of the coating. The powder is deposited using plasma spraying at atmospheric pressure (APS. The plasma gas is He, which is an inert gas and does not react with the powder; it produces dense plasma with lower heat content and less incorporated ambient air in the plasma jet thus reducing temperature decomposition and decarburization of Cr3C2 carbide.. In this study, three groups of coatings were deposited with three different powder feed rates of: 30, 45 and 60 g/min. The  coating with the best properties was deposited on the inlet flange parts of the turbo - jet engine TV2-117A to reduce the influence of vibrations and wear. The structures and the mechanical properties of 75Cr3C2 - 25Ni(Cr coatings are analyzed in accordance with the Pratt & Whitney standard. Studies have shown that powder feed rates have an important influence on the mechanical properties and structures of 75Cr3C2 - 25Ni(Cr coatings

  12. Reliability of plasma-sprayed coatings: monitoring the plasma spray process and improving the quality of coatings

    Science.gov (United States)

    Fauchais, P.; Vardelle, M.; Vardelle, A.

    2013-06-01

    As for every coating technology, the reliability and reproducibility of coatings are essential for the development of the plasma spraying technology in industrial manufacturing. They mainly depend on the process reliability, equipment and spray booth maintenance, operator training and certification, implementation and use of consistent production practices and standardization of coating testing. This paper deals with the first issue, that is the monitoring and control of the plasma spray process; it does not tackle the coating characterization and testing methods. It begins with a short history of coating quality improvement under plasma spray conditions over the last few decades, details the plasma spray torches used in the industry, the development of the measurements of in-flight and impacting particle parameters and then of sensors. It concludes with the process maps that describe the interrelations between the operating parameters of the spray process, in-flight particle characteristics and coating properties and with the potential of in situ monitoring of the process by artificial neural networks and fuzzy logic methods.

  13. The Structure and Behavior of Vacuum Plasma Sprayed Overlay Coatings on Nickel Based Superalloys.

    Science.gov (United States)

    1983-06-01

    the oxide -1c the coating. SEA, 85 deg. tilt, 5000X B.30 Dee etched NiCrAl with La which shows no . . 45 uicfc-peg formation. S2, 85 deg. tilt, 50001...34 - ’. . - - .. ., - . . - . - ., . - " - ’ .. . ’ . . - - - . . - . 3:11. IIIULU. An ID PL SM2 ,I- 10 iINSOLIZS .U ainUSUL! ’,’ a. Vendor "IN The structures of both the NiCrAl and CcCrAl type...surface and loose particles exhibited by a pl~asma sprayed NiCrAl cocit.ng. * SEE, 1000X Figure B.13 Plasma s Frayed coating by Vendor "B" with low ir

  14. Gas Permeability of Porous Plasma-Sprayed Coatings

    Science.gov (United States)

    Wittmann-Ténèze, K.; Caron, N.; Alexandre, S.

    2008-12-01

    For different applications, such as solid oxide fuel cells, there is an interest in understanding the relationship between the microstructure and the gas permeability of plasma-sprayed coatings. Nevertheless, plasma spraying processes allow to elaborate coatings with singular microstructures, depending strongly on the initial material and plasma operating conditions. And so, the evolution of permeability is not directly linked to the porosity. In this work, coatings were manufactured using different initial feedstock and spray parameters to obtain various microporous structures. Measurements of their permeation with the pressure drop method and their open porosity just as the observation of the morphology and the structure by optical microscopy were achieved. The different data show that the evolution of the gas permeability with the open porosity follows the Kozeny-Carman equation. This result correlated with the microstructural observation highlights the relationship between the permeability and the physical properties of porous plasma-sprayed layers.

  15. Process optimization of ultrasonic spray coating of polymer films

    DEFF Research Database (Denmark)

    Bose, Sanjukta; Keller, Stephan Sylvest; Boisen, Anja

    2013-01-01

    In this work we have performed a detailed study of the influence of various parameters on spray coating of polymer films. Our aim is to produce polymer films of uniform thickness (500 nm to 1 μm) and low roughness compared to the film thickness. The coatings are characterized with respect...... these two regimes, where we obtain a film of desired quality. Both with increasing nozzle-substrate distance and temperature, the deposition moves from a wet state to a dry regime. Similar results are also achieved for solvents with low boiling points. Finally, we study film formation during spray coating...... to thickness, roughness (profilometer), and morphology (optical microscopy). Polyvinylpyrrolidone (PVP) is used to do a full factorial design of experiments with selected process parameters such as temperature, distance between spray nozzle and substrate, and speed of the spray nozzle. A mathematical model...

  16. Plasma spray forming of tungsten coatings on copper electrodes

    Institute of Scientific and Technical Information of China (English)

    JIANG Xian-liang(蒋显亮); F.Gitzhofer; M.I.Boulos

    2004-01-01

    Both direct current dc plasma and radio frequency induction plasma were used to deposit tungsten coatings on copper electrodes. Fine tungsten powder with mean particle size of 5μm and coarse tungsten powder with particle size in the range from 45 μm to 75 μm were used as plasma spray feedstock. It is found that dc plasma is only applicable to spray the fine tungsten powder and induction plasma can be used to spray both the coarse powder and the fine powder. The tungsten coating deposited by the induction plasma spraying of the coarse powder is extremely dense. Such a coating with an interlocking structure and an integral interface with the copper substrate demonstrates high cohesion strength and adhesion strength.

  17. Plasma-sprayed thermal barrier coatings: numerical study on damage localization and evolution

    Directory of Open Access Journals (Sweden)

    K. Slámečka

    2016-01-01

    Full Text Available Thermal barrier coatings (TBCs are advanced material systems used to enhance performance and in-service life of components operated at high temperatures in gas turbines and other power-generation devices. Because of complexity, numerical methods became important tools both for design of these coatings and for in-service life estimations and optimization. In this contribution, two main features that affect the TBCs’ performance, namely the roughness of the bond coat and the microstructure of the ceramic top coat, are discussed based on Finite Element Method (FEM and Finite Element Microstructure MEshfree (FEMME simulations that were used to calculate stresses and assess damage within the coating. Roughness data obtained from plasma-sprayed CoNiCrAlY + YSZ coated samples are supplemented to discuss assumptions and results of employed numerical models.

  18. Residual Stresses in Thermal Barrier Coatings for a Cu-8Cr-4Nb Substrate System

    Science.gov (United States)

    Ghosn, Louis J.; Raj, Sai V.

    2002-01-01

    Analytical calculations were conducted to determine the thermal stresses developed in a coated copper-based alloy, Cu-8%(at.%)Cr-4%Nb (designated as GRCop-84), after plasma spraying and during heat-up in a simulated rocket engine environment. Finite element analyses were conducted for two coating systems consisting of a metallic top coat, a pure copper bond coat and the GRCop-84. The through thickness temperature variations were determined as a function of coating thickness for two metallic coatings, a Ni-17%(wt%)Cr-6%Al-0.5%Y alloy and a Ni-50%(at.%)Al alloy. The residual stresses after low-pressure plasma spraying of the NiCrAlY and NiAl coatings on GRCop-84 substrate were also evaluated. These analyses took into consideration a 50.8 mm copper bond coat and the effects of an interface coating roughness. The through the thickness thermal stresses developed in coated liners were also calculated after 15 minutes of exposure in a rocket environment with and without an interfacial roughness.

  19. Selected Properties Of Thermally Sprayed Oxide Ceramic Coatings

    Directory of Open Access Journals (Sweden)

    Czupryński A.

    2015-09-01

    Full Text Available The article presents the results of the study on exploitation properties of flame sprayed ceramic coatings produced by oxide ceramic material in the form of powder on the aluminum oxide Al2O3 matrix with 3% titanium oxide TiO2 addition and also on the zirconium oxide (ZrO2 matrix with 30% calcium oxide (CaO on the substrate of unalloyed structural steel of S235JR grade. As a primer powder, metallic powder on the base of Ni-Al-Mo has been applied. Plates with dimensions of 5×200×300 mm and also front surfaces of ∅40×50 mm cylinders have been flame sprayed. Spraying of primer coating has been done using RotoTec 80 torch and external specific coating has been done with CastoDyn DS 8000 torch. Investigations of coating properties are based on metallography tests, phase composition research, measurement of microhardness, coating adhesion to the ground research (acc. to EN 582:1996 standard, abrasive wear resistance (acc. to ASTM G65 standard and erosion wear resistance (acc. to ASTM G76-95 standard and thermal stroke study. Performed tests have shown that the flame spraying with 97%Al2O3 powder containing 3% TiO2 and also by the powder based on zirconium oxide (ZrO2 containing 30% calcium oxide (CaO performed in a wide range of technological parameters allow to obtain high quality ceramic coatings with thickness up to ca. 500 μm on a steel substrate. The primer coating sprayed with the Ni-Al-Mo powder to the steel substrate and external coatings sprayed has the of mechanical bonding character. The coatings are characterized by high adhesion to the substrate and also high erosion and abrasive wear resistance and the resistance for cyclic thermal stroke.

  20. Metal flame spray coating protects electrical cables in extreme environment

    Science.gov (United States)

    Brady, R. D.; Fox, H. A.

    1967-01-01

    Metal flame spray coating prevents EMF measurement error in sheathed instrumentation cables which are externally attached to cylinders which were cooled on the inside, but exposed to gamma radiation on the outside. The coating provides a thermoconductive path for radiation induced high temperatures within the cables.

  1. Characterization and High-Temperature Erosion Behaviour of HVOF Thermal Spray Cermet Coatings

    Science.gov (United States)

    Kumar, Pardeep; Sidhu, Buta Singh

    2016-01-01

    High-velocity oxygen fuel (HVOF) thermal spray, carbide-cermet-based coatings are usually employed in high-temperature erosive and erosive-corrosive environments. Extensive literature is available on high-temperature erosion performance of HVOF coatings under moderate to low particle flux and velocities for application in boiler tubes. This research work presents the characterization and high-temperature erosion behaviour of Cr3C2-25NiCr and WC-10Co-4Cr HVOF-sprayed coatings. Coatings were formulated on the substrate steel of type AISI 304, commonly used for the fabrication of pulverized coal burner nozzles (PCBN). Erosion testing was carried out in high-temperature air-jet erosion tester after simulating the conditions akin to that prevailing in PCBN in the boiler furnace. The coatings were tested for erosion behaviour at different angles and temperatures by freezing other test parameters. Brittle erosion behaviour was depicted in erosion testing, and the coatings couldn't restrain the erodent attacks to protect the substrate. High particle velocity and high particle flux were attributed to be the reasons of extensive erosive weight loss of the coatings. The surface morphology of the eroded specimens was analysed from back-scattered electron images to depict the probable mechanism of material removal. The coatings were characterized with optical microscopy, SEM-EDS analysis, XRD analysis, micro-hardness testing, porosity measurements, surface roughness testing and bond strength testing. The work was undertaken to investigate the performance of the selected coatings in highly erosive environment, so as to envisage their application in PCBNs for protection against material degradation. The coatings could only sustain in oblique impact erosion at room temperature and depleted fully under all other conditions.

  2. Monoclinic zirconia distributions in plasma-sprayed thermal barrier coatings

    Science.gov (United States)

    Lance, M. J.; Haynes, J. A.; Ferber, M. K.; Cannon, W. R.

    2000-03-01

    Phase composition in an air plasma-sprayed Y2O3-stabilized ZrO2 (YSZ) top coating of a thermal barrier coating (TBC) system was characterized. Both the bulk phase content and localized pockets of monoclinic zirconia were measured with Raman spectroscopy. The starting powder consisted of ˜15 vol.% monoclinic zirconia, which decreased to ˜2 vol.% in the as-sprayed coating. Monoclinic zirconia was concentrated in porous pockets that were evenly distributed throughout the TBC. The pockets resulted from the presence of unmelted granules in the starting powder. The potential effect of the distributed monoclinic pockets on TBC performance is discussed.

  3. Quantification of corrosion resistance of a new-class of criticality control materials: thermal-spray coatings of high-boron iron-based amorphous metals - Fe49.7Cr17.7Mn1.9Mo7.4W1.6B15.2C3.8Si2.4

    Energy Technology Data Exchange (ETDEWEB)

    Farmer, J C; Choi, J S; Shaw, C K; Rebak, R; Day, S D; Lian, T; Hailey, P; Payer, J H; Branagan, D J; Aprigliano, L F

    2007-03-28

    An iron-based amorphous metal, Fe{sub 49.7}Cr{sub 17.7}Mn{sub 1.9}Mo{sub 7.4}W{sub 1.6}B{sub 15.2}C{sub 3.8}Si{sub 2.4} (SAM2X5), with very good corrosion resistance was developed. This material was produced as a melt-spun ribbon, as well as gas atomized powder and a thermal-spray coating. Chromium (Cr), molybdenum (Mo) and tungsten (W) provided corrosion resistance, and boron (B) enabled glass formation. The high boron content of this particular amorphous metal made it an effective neutron absorber, and suitable for criticality control applications. Earlier studies have shown that ingots and melt-spun ribbons of these materials have good passive film stability in these environments. Thermal spray coatings of these materials have now been produced, and have undergone a variety of corrosion testing, including both atmospheric and long-term immersion testing. The modes and rates of corrosion have been determined in the various environments, and are reported here.

  4. Microstructural studies of thermal spray coatings for biomedical applications

    Science.gov (United States)

    Sun, Limin

    2002-01-01

    This project aims to address two major concerns with the use of hydroxyapatite [Ca10(PO4)6(OH)2, i.e., HA] coatings; i.e., (i) the resorption of the coating, and (ii) the resorption of bone. The objective is to optimize coating design through microstructural studies of two coating systems: a HA coating and a HA/polymer composite coating. For the HA coating, the HA powders were atmospherically plasma sprayed (APS) using various process parameters. The phase, structure and microstructure of the coatings were investigated and the mechanical property and dissolution behavior measured. Both crystallinity and hydroxyl contents decreased with increasing spray power and stand-off distance (SOD), and increased from the coating interface to surface. Impurity phase contents increased with increasing spray power. Crystallinity alone cannot reflect coating quality due to the existence of various HA, i.e., unmelted, recrystallized and dehydroxylated, and the gradient structure. Coating microstructure varied from a porous structure to a smooth glassy structure or a typical lamellar structure, and some newly formed nanocrystalline regions were revealed. These effects were associated with the temperature-time experiences of particles, their cooling rates and the heat and hydroxyl accumulation during coating buildup. Different coating properties and performance resulted from the characteristic differences. The coating with highest recrystallization displayed the highest microhardness. Dissolution of all coatings reached a saturation value much lower compared to their pulverized counterparts in a fresh solution despite a higher and similar dissolution in the initial immersion stage. The coating with higher recrystallization exhibited higher saturation value. Microstructural analysis indicated the complete and preferential dissolution of amorphous and impurity phases and some precipitation of apatite observable for coatings with higher recrystallization. For the composite coating, HA

  5. DURABILITY AND TRIBOLOGICAL PROPERTIES OF THERMALLY SPRAYED WC CERMET COATING IN LUBRICATED ROLLING WITH SLIDING CONTACT

    Directory of Open Access Journals (Sweden)

    Mohammad Ali

    2010-09-01

    Full Text Available Durability and tribological properties of thermally sprayed WC-Cr-Ni cermet coating were investigated experimentally in lubricated rolling with sliding contact conditions. By means of the high energy type flame spraying (Hi-HVOF method, the coating was formed onto the axially ground and circumferentially ground roller specimens made of a thermally refined carbon steel. In the experiments, the WC cermet coated steel roller was mated with the carburized hardened steel roller without coating in line contact condition. The coated roller was mated with the smooth non-coated roller under a contact pressure of 1.0 or 1.2 GPa, and it was mated with the rough non-coated roller under a contact pressure of 0.6 or 0.8 GPa. As a result, it was found that in general, the coating on the circumferentially ground substrate shows a lower durability compared with that on the axially ground substrate and this difference appears more distinctly for the higher contact pressure for both smooth mating surface and rough mating surface. It was also found that there are significant differences in the tribological properties of WC cermet coating depending on the contact pressure. In addition, depending on the smooth or rough mating surface, remarkable differences in the tribological properties were found.

  6. Inter-diffusion between Co3O4 coatings and the oxide scale on Fe-22Cr

    DEFF Research Database (Denmark)

    Hansson, Anette Nørgaard; Linderoth, Søren; Mogensen, Mogens Bjerg

    2007-01-01

    The oxidation behaviour of a commercially available Fe-22Cr alloy coated with a Co3O4 layer by spray-painting or plasma-spraying was investigated at 1173K in air with 1% H2O and compared to the oxidation behaviour of the non-coated alloy. The oxide morphology was examined with X-ray diffraction, ...... plasma-sprayed and the non-coated samples. The difference in morphology is suggested to be an effect of SiO2 nucleation assisted by Kirkendall void formation....

  7. Hot corrosion performance of a NiCr coated Ni-based alloy

    Energy Technology Data Exchange (ETDEWEB)

    Sidhu, T.S.; Prakash, S.; Agrawal, R.D. [Indian Institute of Technology, Roorkee (India)

    2006-07-15

    The hot corrosion performance of high velocity oxy-fuel sprayed Ni-20Cr wire coating on a Ni-based superalloy is evaluated for 1000 h at 900{sup o}C under cyclic conditions in a coal-fired boiler. The performance of bare and Ni-20Cr coated Superni 75 is assessed via thermogravimetric data, metal thickness loss corresponding to the corrosion scale formation, scale thickness loss and the depth of internal corrosion attack. The better hot corrosion resistance of the coated alloy is mainly attributed to the formation of a thick band of chromium oxide just above the scale-substrate interface and chromium oxide stringers along the splat boundaries, as well as to the nickel oxide and the dense and uniform fine grain structure of the as sprayed coating.

  8. Process optimization of ultrasonic spray coating of polymer films.

    Science.gov (United States)

    Bose, Sanjukta; Keller, Stephan S; Alstrøm, Tommy S; Boisen, Anja; Almdal, Kristoffer

    2013-06-11

    In this work we have performed a detailed study of the influence of various parameters on spray coating of polymer films. Our aim is to produce polymer films of uniform thickness (500 nm to 1 μm) and low roughness compared to the film thickness. The coatings are characterized with respect to thickness, roughness (profilometer), and morphology (optical microscopy). Polyvinylpyrrolidone (PVP) is used to do a full factorial design of experiments with selected process parameters such as temperature, distance between spray nozzle and substrate, and speed of the spray nozzle. A mathematical model is developed for statistical analysis which identifies the distance between nozzle and substrate as the most significant parameter. Depending on the drying of the sprayed droplets on the substrate, we define two broad regimes, "dry" and "wet". The optimum condition of spraying lies in a narrow window between these two regimes, where we obtain a film of desired quality. Both with increasing nozzle-substrate distance and temperature, the deposition moves from a wet state to a dry regime. Similar results are also achieved for solvents with low boiling points. Finally, we study film formation during spray coating with poly (D,L-lactide) (PDLLA). The results confirm the processing knowledge obtained with PVP and indicate that the observed trends are identical for spraying of other polymer films.

  9. Hot corrosion resistance of high-velocity oxyfuel sprayed coatings on a nickel-base superalloy in molten salt environment

    Science.gov (United States)

    Sidhu, T. S.; Prakash, S.; Agrawal, R. D.

    2006-09-01

    No alloy is immune to hot corrosion attack indefinitely. Coatings can extend the lives of substrate materials used at higher temperatures in corrosive environments by forming protective oxides layers that are reasonably effective for long-term applications. This article is concerned with studying the performance of high-velocity oxyfuel (HVOF) sprayed NiCrBSi, Cr3C2-NiCr, Ni-20Cr, and Stellite-6 coatings on a nickel-base superalloy at 900 °C in the molten salt (Na2SO4-60% V2O5) environment under cyclic oxidation conditions. The thermogravimetric technique was used to establish kinetics of corrosion. Optical microscope, x-ray diffraction, scanning electron microscopy/electron dispersive analysis by x-ray (SEM/EDAX), and electron probe microanalysis (EPMA) techniques were used to characterize the as-sprayed coatings and corrosion products. The bare superalloy suffered somewhat accelerated corrosion in the given environmental conditions. whereas hot corrosion resistance of all the coated superalloys was found to be better. Among the coating studied, Ni-20Cr coated superalloy imparted maximum hot corrosion resistance, whereas Stellite-6 coated indicated minimum resistance. The hot corrosion resistance of all the coatings may be attributed to the formation of oxides and spinels of nickel, chromium, or cobalt.

  10. Nanostructured Sulfide Composite Coating Prepared by Atmospheric Plasma Spraying

    Institute of Scientific and Technical Information of China (English)

    关耀辉

    2006-01-01

    Nanostructured FeS-SiC coating was deposited by atmospheric plasma spraying (APS). The microstructure and phase composition of the coating were characterized with SEM and XRD, respectively. In addition, the size distribution of the reconstituted powders and the porosity of the coating have been measured. It was found that the reconstitiuted powers with sizes in the range of 20 to 80 μm had excellent flowability and were suitable for plasma spraying process. The assprayed FeS-SiC composite coating exhibited a bimodal distribution with small grains (30~80nm) and large grains (100~200nm). The coating was mainly composed of FeS and SiC, a small quantity of Fe1-x S and oxide were also found. The porosity of the coating was approximately 19 %.

  11. Silicon Strengthened CrAlVN Coatings

    Institute of Scientific and Technical Information of China (English)

    Qiang LI; Yue-xiu QIU; Bo LI; Dong-liang ZHAO; De-en SUN; De-hui LI

    2015-01-01

    CrAlVN coatings are of good intrinsic mechanical and tribological properties but lack of strength.Silicon can provide nitride coating high strength and excellent oxidation resistance.Logically,the combination of CrAlVN and Si should provide a good candidate for dry machining.The effect of silicon content on CrAlSiVN coating′s me-chanical,tribological properties and oxidation resistance was investigated.The coatings were deposited on cemented tungsten carbide and Si wafer (100)substrates in an in-line magnetron sputtering system.Grazing incidence X-ray diffractometer,scanning electron microscopy,atomic force microscopy,transmission electron microscopy,electron probe micro-analyzer,X-ray photoelectron spectroscopy and Auger electron spectroscopy were employed to charac-terize the microstructure and chemistry.Nanoindentation and ball-on-disc tribo-tester were used in characterization of the mechanical and tribological properties.Incorporating with silicon,the CrAlVN coating was strengthened (hard-ness:21.2 GPa up to 38.7 GPa);even after 2 h exposure to 700 ℃ in air,the hardness still maintains at 11.0 GPa.

  12. Study on Bond Ability of Arc-Spraying Coatings with Different Surface Pretreatment on Cast-Iron

    Institute of Scientific and Technical Information of China (English)

    HAO Jian-jun; MA Yue-jin; SHEN Yu-zeng

    2004-01-01

    Arc spraying coatings are widely used in various applications, but uncommon in cast iron substrate. Different surface pretreatment technology is tested on substrates of gray cast iron. Surface roughness and residual stress were measured by TR200 and X-ray diffraction analyzer. Influence of different surface pretreatment methods ( dry blasting and fusebond) on roughness and residual stress was analyzed. The arc-sprayed coatings of wire 3Cr13 (φ2mm) on gray cast iron substrate is studied. The microstructure and interface of bonding layer were observed by SEM. The bond strength was taken by tensile test. Results show that bond strength with grit blasting is higher than fuse-bond; it is feasible to make wire 3Cr13 coating with arc spraying on cast iron substrate roughened by grit blasting.

  13. Preparation, Microstructure and Properties of NiO-Cr_2O_3-TiO_2 Infrared Radiation Coating

    Institute of Scientific and Technical Information of China (English)

    Wu Chen; Weiping Ye; Xudong Cheng; Wei Duan; Fang Mao; Deliang Li

    2009-01-01

    The spherical agglomerated particles were fabricated by spray drying with the powders of NiO, Cr_2O_3 and TiO2. Plasma spray power, which has good property of flowability, was acquired by heat treatment from the particles at 1200℃ in the reducing atmosphere. Dark and uniform coating of More than 50 μm thick was deposited on the copper sheet substrate by plasma spraying. It is found that the infrared normal total emissivity of the coating is up to 0.91 at 600℃ by infrared radiation testing. The X-ray diffraction analysis shows that the formation of (Cr_0.88Ti_0.12)_2O_3 and spinel structural NiCr_2O_4 in the coating is the main reason for high efficient infrared radiation, and the phase structure and performance of coating is favorable under the thermal cycle between room temperature and 600℃.

  14. Tribological Properties of WC-12Co/NiCrAl Composite Coating Prepared by Plasma Spraying%等离子喷涂WC-12Co/NiCrAl复合涂层的摩擦磨损特性

    Institute of Scientific and Technical Information of China (English)

    郭华锋; 田宗军; 黄因慧

    2014-01-01

    以NiCrAl涂层为粘结层,用等离子喷涂工艺在TC4钛合金表面制备了WC-12Co/NiCrAl复合涂层.通过扫描电镜(SEM)、能谱仪(EDS)、X射线衍射仪(XRD)和显微硬度仪等手段分析了涂层微观形貌、化学成分和显微硬度,并用磨损试验考察了WC-12Co/NiCrAl复合涂层的摩擦磨损特性.结果表明:WC-12Co涂层表面未熔颗粒较多,涂层截面孔隙率为10.2%;WC发生部分分解,出现W2C、Co6 W6C等新相;涂层与基体结合界面为机械结合十局部微冶金结合方式;显微硬度为双态Weibull分布,呈现不同位置结构的差异化.WC-12Co涂层表现出良好的减摩及耐磨性能,同载荷下摩擦因数低于基体,磨损失重为基体的1/10,磨粒磨损是其主要磨损机制.

  15. 等离子喷涂NiCrBSi涂层接触疲劳过程中残余应力变化规律研究%Study on the Residual Stress of Plasma Sprayed NiCrBSi Coating in Contact Fatigue Process

    Institute of Scientific and Technical Information of China (English)

    李国禄; 王韶云; 王海斗; 刘金海; 朴钟宇

    2012-01-01

    The NiCrBSi alloy coating is deposited on steel (AISI 1045) substrates using supersonic plasma spraying technique. The overall structure of the coating is densification and contained a small amount of micro-defects. Rolling contact fatigue (RCF) life of the coating is investigated using a ball-cm-disc tester under 1.86 Gpa contact stress, and 1 500 r/min rotation velocity. Obtained that the contact fatigue lifetime of coating is 9.0×105 cycle, map of Weibull distribution failure probability is plotted as well. And the failure probability of random cycle is achieved by this Weibull plot under identical work condition. Coating's residual stress at stage of fatigue life is measured by the X-ray equipment. The results show that the residual stress changed by tensile stress into compressive stress when contact fatigue tests start, and the stress rises slowly in the first half of fatigue process while increases sharply in the following procedure, which makes the mid-stage became the critical point of fatigue failure process. Following this law, fatigue stage of coating can be determined, and the catastrophic failure of coating can be prevented effectively.%采用超声速等离子喷涂技术在45钢基体上制备NiCrBSi合金涂层,涂层整体结构致密,含有少量微缺陷.使用球盘式接触疲劳试验机在接触应力为1.86 GPa,转速为1500r/min的条件下对涂层试样进行接触疲劳试验,得到涂层的接触疲劳寿命为9.0×105周次;同时建立Weibull失效概率图,通过该图可以直观地得到在同一工作条件下,涂层任意循环次数的失效概率.测量涂层不同疲劳阶段的残余应力,结果表明:一旦进行接触疲劳试验,其残余应力形式由拉应力迅速转化为压应力,在整个疲劳过程的前半段,应力增强较为缓慢,在疲劳过程的后半段,应力值迅速增大,疲劳过程的中期成为了应力变化的转折点.根据这一规律,可以有效地判定涂层处于疲劳过程的哪

  16. High-Temperature Solid Lubricant Coating by Plasma Spraying Using Metal-Metal Clad Powders

    Science.gov (United States)

    Zhang, Tiantian; Lan, Hao; Yu, Shouquan; Huang, Chuanbing; Du, Lingzhong; Zhang, Weigang

    2017-08-01

    NiCr/Ag-Mo composite coating was fabricated by atmospheric plasma spray technology using clad powders as the feedstock. Its tribological properties at variable temperature were evaluated using a ball-on-disk high-temperature tribometer in air. The results showed that compared with NiCr, the NiCr/Ag-Mo composite coating exhibited better lubrication effect and higher wear resistance at all test temperatures, especially above 600 °C. At 800 °C, NiCr/Ag-Mo composite coating showed the lowest friction coefficient of about 0.2 and its corresponding wear rate reached 2.5 × 10-5 mm3/Nm. Characterizations of NiCr/Ag-Mo composite coating revealed that at temperatures below 400 °C, Ag was smeared and spread onto the wear surface, reducing the friction and wear. At temperature above 500 °C, the Ag2MoO4 lubrication film formed by tribo-oxidation significantly improved the coating's lubrication effect and wear resistance.

  17. Investigation on Interface Structure and Wear-resistant Properties of HVOF Sprayed Carbides Coating onto Copper Substrate

    Institute of Scientific and Technical Information of China (English)

    HOU Li-feng; ZHANG Heng-jin; WEI Ying-hui; YAN Kai; HU Lan-qing; XU Bing-she

    2004-01-01

    In this paper, we deposited carbides on copper substrate by High velocity oxy-fuel (HVOF) spraying. The structure of the coating and microstructure of the substrate-coating interface have been investigated by means of scanning electron microscope (SEM) and transmission electron microscopy (TEM). We observed the worn surface of the coating and investigated the wear mechanism. The results show that the microstructure of the interface between HVOF sprayed coating and substrate which consists of the amorphous layers, nanocrystalls in the coating and dislocation cells in copper substrate,etc. is complex. The amorphous layers are formed from heated adhesion after rapidly cooling, while the nanocrystalls come from the fragmentation of half-molten carbides. At the same time we found that the wear-resistant properties of the WC-Co coating is better than that of Cr3C2-NiCr coating at room temperature. The early wear-resistance of the HVOF sprayed coating is poor because of the roughness of its surface or bad bond of hard composite particles. The high velocity of molten droplets is propitious to fill up the interspaces between carbides, so as to make the coating more compact and reduce its porosities, thus the wear-resistance of carbides coatings is improved.

  18. Investigation on Interface Structure and Wear-resistant Properties of HVOF Sprayed Carbides Coating onto Copper Substrate

    Institute of Scientific and Technical Information of China (English)

    HOULi-feng; ZHANGHeng-jin; WEIYing-hui; YANKai; HULan-qing; XUBing-she

    2004-01-01

    In this paper, we deposited carbides on copper substrate by High velocity oxy-fuel (HVOF) spraying. The structure of the coating and microstructure of the substrate-coating interface have been investigated by means of scanning electron microscope (SEM) and transmission electron microscopy (TEM). We observed the worn surface of the coating and investigated the wear mechanism. The results show that the microstructure of the interface between HVOF sprayed coating and substrate which consists of the amorphous layers, nanocrystalls in the coating and dislocation cells in copper substrate, etc. is complex. The amorphous layers are formed from heated adhesion after rapidly cooling, while the nanocrystalls come from the fragmentation of half-molten carbides. At the same time we found that the wear-resistant properties of the WC-Co coating is better than that of Cr3C2-NiCr coating at room temperature. The early wear-resistance of the HVOF sprayed coating is poor because of the roughness of its surface or bad bond of hard composite particles. The high velocity of molten droplets is propitious to fill up the interspaces between carbides, so as to make the coating more compact and reduce its porosities, thus the wear-resistance of carbides coatings is improved.

  19. Research on Microstructure and Performance of MoB/CoCr Cermet Coatings Sprayed on 20G Steel Surface%20G钢表面喷涂MoB/CoCr金属陶瓷涂层的组织性能研究

    Institute of Scientific and Technical Information of China (English)

    陈袅; 张仁元; 李风

    2011-01-01

    MoB/CoCr cermet coatings were deposited on 20G steel by low pressure plasma spraying (LPPS). The microstructure and phase composition of coatings were characterized by XRD, SEM and EDAX, and the bond strength and thermal shock resistance performance were studied. The results show that phase component of powder and coating had little change. The coatings are dense and have excellent combination with substrate. The main constituents of coatings remain invariant and the coatings have excellent performance of bond strength and thermal shock resistance. The MoB/CoCr coating has much higer durability after 1080 h immersion test in the molten Al-12.07% Si.%在20G钢换热管表面上利用低压等离子喷涂(UPS)制备MoB/CoCr金属陶瓷涂层.采用X射线衍射(XRD)、扫描电镜(SEM)、能谱分析(EDAX)对涂层的物相组成、微观组织和成分进行了表征,并对涂层的结合强度和抗热震性能进行研究.研究表明:喷涂前后涂层的物相相差不大,涂层为层状结构;涂层与20G基体之间、表面涂层与过渡涂层之间结合良好,涂层致密;涂层具有良好的结合强度和抗热震性能,在熔融AI-12.07% Si中经过1080h腐蚀后,涂层基本保持完好,具有很好的抗熔融铝硅腐蚀性能.

  20. Milestones in Functional Titanium Dioxide Thermal Spray Coatings: A Review

    Science.gov (United States)

    Gardon, M.; Guilemany, J. M.

    2014-04-01

    Titanium dioxide has been the most investigated metal oxide due to its outstanding performance in a wide range of applications, chemical stability and low cost. Coating processes that can produce surfaces based on this material have been deeply studied. Nevertheless, the necessity of coating large areas by means of rapid manufacturing processes renders laboratory-scale techniques unsuitable, leading to a noteworthy interest from the thermal spray (TS) community in the development of significant intellectual property and a large number of scientific publications. This review unravels the relationship between titanium dioxide and TS technologies with the aim of providing detailed information related to the most significant achievements, lack of knowhow, and performance of TS TiO2 functional coatings in photocatalytic, biomedical, and other applications. The influence of thermally activated techniques such as atmospheric plasma spray and high-velocity oxygen fuel spray on TiO2 feedstock based on powders and suspensions is revised; the influence of spraying parameters on the microstructural and compositional changes and the final active behavior of the coating have been analyzed. Recent findings on titanium dioxide coatings deposited by cold gas spray and the capacity of this technology to prevent loss of the nanostructured anatase metastable phase are also reviewed.

  1. Superior Thermal Barrier Coatings Using Solution Precursor Plasma Spray

    Science.gov (United States)

    Jordan, E. H.; Xie, L.; Gell, M.; Padture, N. P.; Cetegen, B.; Ozturk, A.; Ma, X.; Roth, J.; Xiao, T. D.; Bryant, P. E. C.

    2004-03-01

    A novel process, solution precursor plasma spray (SPPS), is presented for depositing thermal barrier coatings (TBCs), in which aqueous chemical precursors are injected into a standard direct current plasma spray system. The resulting coatings microstructure has three unique features: (1) ultra fine splats (1 µm), (2) nanometer and micron-sized interconnected porosity, and (3) closely spaced, through-thickness cracks. Coatings over 3 mm thick can be readily deposited using the SPPS process. Coating durability is excellent, with SPPS coatings showing, in furnace cycling tests, 2.5 times the spallation life of air plasma coatings (APS) and 1.5 times the life of electron beam physical vapor deposited (EB-PVD) coatings. The conductivity of SPPS coatings is lower than EB-PVD coatings and higher than the best APS coatings. Manufacturing cost is expected to be similar to APS coatings and much lower than EB-PVD coatings. The SPPS deposition process includes droplet break-up and material arriving at the deposition surface in various physical states ranging from aqueous solution, gel phase, to fully-molten ceramic. The relation between the arrival state of the material and the microstructure is described.

  2. Comparative study of Cr{sub 3}C{sub 2}-NiCr coatings obtained by HVOF and hard chromium coatings

    Energy Technology Data Exchange (ETDEWEB)

    Guilemany, J.M. [CPT Thermal Spray Centre, Materials Engineering, Dept. Ciencia de Materiales e Ingenieria Metalurgica, Universidad de Barcelona, C/Marti i Franques 1, CP 08028 Barcelona (Spain)]. E-mail: cpt-cmem@ub.edu; Espallargas, N. [CPT Thermal Spray Centre, Materials Engineering, Dept. Ciencia de Materiales e Ingenieria Metalurgica, Universidad de Barcelona, C/Marti i Franques 1, CP 08028 Barcelona (Spain); Suegama, P.H. [CPT Thermal Spray Centre, Materials Engineering, Dept. Ciencia de Materiales e Ingenieria Metalurgica, Universidad de Barcelona, C/Marti i Franques 1, CP 08028 Barcelona (Spain); Dep. Fisico-Quimica, Instituto de Quimica, Universidade Estadual Paulista, UNESP, CP 355, 14801-970 Araraquara, SP (Brazil); Benedetti, A.V. [CPT Thermal Spray Centre, Materials Engineering, Dept. Ciencia de Materiales e Ingenieria Metalurgica, Universidad de Barcelona, C/Marti i Franques 1, CP 08028 Barcelona (Spain) and Dep. Fisico-Quimica, Instituto de Quimica, Universidade Estadual Paulista, UNESP, CP 355, 14801-970 Araraquara, SP (Brazil)]. E-mail: benedeti@iq.unesp.br

    2006-10-15

    In the present work the corrosion resistance of micro-cracked hard chromium and Cr{sub 3}C{sub 2}-NiCr (HVOF) coatings applied on a steel substrate have been compared using open-circuit potential (E {sub OC}) measurements, electrochemical impedance spectroscopy (EIS) and polarization curves. The coatings surfaces and cross-section were characterized before and after corrosion tests using optical microscopy (OM) and scanning electron microscopy (SEM). After 18 h of immersion, the open-circuit potential values were around -0.50 and -0.25 V/(Ag vertical bar AgCl vertical bar KCl{sub sat}) for hard chromium and Cr{sub 3}C{sub 2}-NiCr, respectively. The surface analysis done after 12 h of immersion showed iron on the hard chromium surface inside/near surface cracks, while iron was not detected on the Cr{sub 3}C{sub 2}-NiCr surface even after 18 h. For longer immersion time hard chromium was more degraded than thermal sprayed coating. For hard chromium coating a total resistance values between 50 and 80 k{omega} cm{sup 2} were measured and two well-defined time constants were observed, without significant change with the immersion time. For Cr{sub 3}C{sub 2}-NiCr coating the total impedance diminished from around 750 to 25 k{omega} cm{sup 2} as the immersion time increased from 17 up to 132 h and two overlapped time constants were also observed. Polarization curves recorded after 18 h of immersion showed a lower current and higher corrosion potential for Cr{sub 3}C{sub 2}-NiCr coating than other samples studied.

  3. Low porosity and fine coatings produced by a new type nozzle of high velocity arc spray gun

    Institute of Scientific and Technical Information of China (English)

    Wang Ruijun; Zhang Tianjian; Xu Lin; Huang Xiaoou

    2006-01-01

    The new designed high-velocity arc spray gun with three different nozzles is developed to match the DZ400 arc spray system, which can produce the coatings with the structure of superfine and low porosity.This system can be used to spray three normal wires such as 4Cr13, FeCrAl and 7Cr13 (flux cored wires).Using the scanning electron microscope (SEM) to analyze shape and particles size that sprayed by the nozzles with different parameters, as well as with the S-3500N SEM and the energy spectrum analytic ( ESA ) instrument to identify the content of the oxides, porosity and thickness of the coatings, we get the result that the porosity in the coatings of solid wire is less than 3%, of the flux-cored wires is less than 5%, and the distribution of the coatings sprayed by the nozzle with secondary supplementary airflow is typically shown in the form of highdensity lamellarsplat structure and the average lamellar thickness is around 5 μm.

  4. Relationship Between Properties and Thickness of Plasma Sprayed NiCrAl Coatings%等离子喷涂NiCrAl涂层性能与厚度关系研究

    Institute of Scientific and Technical Information of China (English)

    段忠清; 张宝霞; 王泽华; 林萍华

    2009-01-01

    采用优化工艺参数,在45钢基体表面等离子喷涂不同厚度(100、250、300和550μm)NiCrAl涂层,研究了涂层厚度与涂层粘结强度、硬度、孔隙率的关系.结果表明,涂层厚度增加,粘结强度、显微硬度随之减小,粘结强度分别为76.6、43.2、34.4和21.4MPa,显微硬度分别为321、290、245和220HV;涂层厚度增加,孔隙率增加,分别为0.42%、0.49%、0.84%和1.13%.

  5. Research on the properties of arc spraying NiCrAl gradient coatings%电弧热喷涂NiCrAl梯度涂层的性能研究

    Institute of Scientific and Technical Information of China (English)

    唐鹏; 曹盛强; 梁天权; 赵颖超; 邓运来; 刘泽

    2009-01-01

    采用电弧热喷涂技术在45#基体表面喷涂制备了NiCrAl梯度涂层,并对涂层的组织分布、结合强度、显微硬度和热腐蚀性能进行了试验研究.结果表明,梯度涂层的组织表现出宏观的不均匀性和微观的连续性的特征;热扩散态的结合强度、显微硬度优于制备态的;涂层成分的梯度化有利于热腐蚀性能的提高.

  6. 等离子喷涂NiCrAl涂层残余应力模拟分析%Analysis on Residual Stresses of Plasma Sprayed NiCrAl Coatings

    Institute of Scientific and Technical Information of China (English)

    段忠清; 张宝霞; 王泽华

    2009-01-01

    建立了模拟涂层残余应力的数学模型,对等离子喷涂不同厚度NiCrAl涂层的残余应力进行了模拟,结果表明:由于涂层与基体的热膨胀系数不匹配等原因,在界面等区域存在严重的应力集中;涂层内部的残余应力水平,随涂层厚度增加而增加;涂层中的轴向应力、径向应力和切向应力主要为拉应力,径向应力是最主要的应力.

  7. Characterization of oxide scales to evaluate high temperature oxidation behavior of Ni-20Cr coated superalloys

    Energy Technology Data Exchange (ETDEWEB)

    Singh, H. [Mechanical Engineering Department, BBSB Engineering College, Fatehgarh Sahib 140407 (India)], E-mail: hnr97@yahoo.com; Puri, D.; Prakash, S. [Metallurgical and Materials Engineering Department, Indian Institute of Technology Roorkee, Roorkee 247 667 (India); Maiti, Rabindranath [Central Research Facilities, Indian Institute of Technology Kharaghpur, Kharaghpur (India)

    2007-08-25

    Modern thermal spray processes such as plasma spraying are usually considered to deposit high-chromium, nickel-chromium coatings onto the superalloys to enhance their high temperature oxidation resistance. The purpose of these coatings is to form long-lasting oxidation protective scales. In the current investigation, Ni-20Cr alloy powder was deposited on three Ni-base superalloys; Superni 75, Superni 600 and Superni 601 by shrouded plasma spray process. Oxidation kinetics was established for the uncoated as well as the coated superalloys in air at 900 deg. C under cyclic conditions for 50 cycles by thermogravimetric technique. Each cycle consisted of 1 h heating followed by 20 min of cooling in air. All the coated superalloys nearly followed the parabolic rate law of oxidation. X-ray diffraction (XRD) and scanning electron microscopy/energy dispersive X-ray (SEM/EDAX) techniques were used to characterise the oxide scales. The coating was found to be successful in maintaining its integrity with the superalloy substrates in all the cases. The oxide scales formed on the oxidized coated superalloys were found to be intact and spallation-free in general. The XRD analysis revealed the presence of phase like NiO, Cr{sub 2}O{sub 3} and NiCr{sub 2}O{sub 4} in the oxide scales. The XRD results were further supported by the SEM/EDAX analyses.

  8. Investigation on plasma-sprayed ZrO2 thermal barrier coating on nickel alloy substrate

    Institute of Scientific and Technical Information of China (English)

    卢安贤; 常鹰; 蔡小梅

    2002-01-01

    The thermal barrier coatings with NiCrAlY alloy bonding layer, NiCrAlY-Y2O3 stabilized ZrO2 transition layer and Y2O3 stabilized ZrO2 ceramic layer are prepared on nickel alloy substrates using the plasma spray technique. The relationship among the composition, structure and property of the coatings are investiga-ted by means of optical microscope, scanning electronic microscope and the experiments of thermal shock resistance cycling and high temperature oxidation resistance. The results show that the structure design of introdu-cing a transition layer between Ni alloy substrate and ZrO2 ceramic coating guarantees the high quality and properties of the coatings; ZrO2 coatings doped with a little SiO2 possesses better thermal shock resistance and more excellent hot corrosion resistance as compared with ZrO2 coating materials without SiO2 ;the improvement in performance of ZrO2 coating doped with SiO2 is due to forming more dense coating structure by self- closing effects of the flaws and pores in the ZrO2 coatings.

  9. Processing of AlCoCrFeNiTi high entropy alloy by atmospheric plasma spraying

    Science.gov (United States)

    Löbel, M.; Lindner, T.; Kohrt, C.; Lampke, T.

    2017-03-01

    High Entropy Alloys (HEA) are gaining increasing interest due to their unique combination of properties. Especially the combination of high mechanical strength and hardness with distinct ductility makes them attractive for numerous applications. One interesting alloy system that exhibits excellent properties in bulk state is AlCoCrFeNiTi. A high strength, wear resistance and high-temperature resistance are the necessary requirements for the application in surface engineering. The suitability of blended, mechanically ball milled and inert gas atomized feedstock powders for the development of atmospheric plasma sprayed (APS) coatings is investigated in this study. The ball milled and inert gas atomized powders were characterized regarding their particle morphology, phase composition, chemical composition and powder size distribution. The microstructure and phase composition of the thermal spray coatings produced with different feedstock materials was investigated and compared with the feedstock material. Furthermore, the Vickers hardness (HV) was measured and the wear behavior under different tribological conditions was tested in ball-on-disk, oscillating wear and scratch tests. The results show that all produced feedstock materials and coatings exhibit a multiphase composition. The coatings produced with inert gas atomized feedstock material provide the best wear resistance and the highest degree of homogeneity.

  10. Spray-Deposited Superconductor/Polymer Coatings

    Science.gov (United States)

    Wise, Stephanie A.; Tran, Sang Q.; Hooker, Matthew W.

    1993-01-01

    Coatings that exhibit the Meissner effect formed at relatively low temperature. High-temperature-superconductor/polymer coatings that exhibit Meissner effect deposited onto components in variety of shapes and materials. Simple, readily available equipment needed in coating process, mean coatings produced economically. Coatings used to keep magnetic fields away from electronic circuits in such cryogenic applications as magnetic resonance imaging and detection of infrared, and in magnetic suspensions to provide levitation and/or damping of vibrations.

  11. Abrasive wear behaviors of high velocity arc sprayed iron aluminum composite coatings

    Institute of Scientific and Technical Information of China (English)

    Weipu Xu; Binshi Xu; Wei Zhang; Zixin Zhu; Yixiong Wu

    2005-01-01

    The High Velocity Arc Spraying (HVAS) technology was used to prepare Fe-Al composite coatings by the adding of different elements into cored wires to obtain different Fe-Al coatings. The added compounds do great effect on the properties of the composite coatings. The microstructures and abrasive wear performances of the coatings were assessed by transmission electron microscopy (TEM), scanning electron microscopy (SEM), and THT07-135 high temperature wear equipment. It was found that the adding of Cr3C2 can greatly increase the room temperature wear behavior, and Fe-Al/WC coatings have adapting periods at the beginning of wear experiment. With the rise of temperature, the wear resistance of Fe-Al/Cr3C2 coatings becomes bad from room temperature to 250℃, and then stable from 250℃ to 550℃; the wear resistance of Fe-Al/WC becomes well with the rise of temperature.The adding of Cr and Ni can also improve wear performances of Fe-Al composite coatings.

  12. Preparation and characterization of LPPS NiCoCrAlYTa coatings for gas turbine engine

    Institute of Scientific and Technical Information of China (English)

    洪瑞江; 周克崧; 王德政; 朱晖朝; 邝子奇

    2001-01-01

    NiCoCrAlYTa coatings have been deposited onto an aircraft gas turbine engine blade using a LPPS unit equipped with a computerized robot. Optimal processing conditions, including spray parameters, the trajectory of the robot, and the synchronized movements between the torch and the blade, have been developed for superior coating properties. Transferred-arc treatment, providing a preheating and a cleaning of the substrate surface, enhances the adherence of the coatings to the substrate. The resulting LPPS coatings show dense and uniform characteristics with ideal hardness, and good corrosion resistance to cycle oxidation.

  13. Plasma-sprayed ceramic coatings for molten metal environments.

    Energy Technology Data Exchange (ETDEWEB)

    Hollis, K. J. (Kendall J.); Peters, M. I. (Maria I.); Bartram, B. D. (Brian D.)

    2002-01-01

    Coating porosity is an important parameter to optimize for plasma-sprayed ceramics which are intended for service in molten metal environments. Too much porosity and the coatings may be infiltrated by the molten metal causing corrosive attack of the substrate or destruction of the coating upon solidification of the metal. Too little porosity and the coating may fail due to its inability to absorb thermal strains. This study describes the testing and analysis of tungsten rods coated with aluminum oxide, yttria-stabilized zirconia, yttrium oxide, and erbium oxide deposited by atmospheric plasma spraying. The samples were immersed in molten aluminum and analyzed after immersion. One of the ceramic materials used, yttrium oxide, was heat treated at 1000 C and 2000 C and analyzed by X-ray diffractography and mercury intrusion porosimetry. Slight changes in crysl nl structure and significant changes in porosity were observed after heat treatments.

  14. Thermal Spray Coatings for Blast Furnace Tuyere Application

    Science.gov (United States)

    Pathak, A.; Sivakumar, G.; Prusty, D.; Shalini, J.; Dutta, M.; Joshi, S. V.

    2015-12-01

    The components in an integrated steel plant are invariably exposed to harsh working environments involving exposure to high temperatures, corrosive gases, and erosion/wear conditions. One such critical component in the blast furnace is the tuyere, which is prone to thermal damage by splashing of molten metal/slag, erosive damage by falling burden material, and corrosion from the ensuing gases. All the above, collectively or independently, accelerate tuyere failure, which presents a potential explosion hazard in a blast furnace. Recently, thermal spray coatings have emerged as an effective solution to mitigate such severe operational challenges. In the present work, five different coatings deposited using detonation spray and air plasma spray techniques were comprehensively characterized. Performance evaluation involving thermal cycling, hot corrosion, and erosion tests was also carried out. Based on the studies, a coating system was suggested for possible tuyere applications and found to yield substantial improvement in service life during actual field trials.

  15. Electrochemical corrosion behavior of arc sprayed Zn-Al coatings

    Institute of Scientific and Technical Information of China (English)

    LIU Yan; ZHU Zi-xin; CHEN Yong-xiong; XU Bin-shi; MA Shi-ning; LI Zhuo-xin

    2004-01-01

    Cored wires and high velocity arc spraying (HVAS) technique were applied to produce high Al content Zn-Al alloy coatings on low carbon steel substrates. The electrochemical corrosion behaviors of Zn, Al and Zn-Al coatings were studied with potentiodynamic measurement in 5 % NaCl solution. Compared with pure Zn, pure Al and Zn-15Al coatings, Zn-26Al coatings show a higher corrosion resistance in salt solution. The potentiodynamic polarization tests show that the corrosion resistance of Zn-Al coatings increases as Al content is raised. Pure Al coating exhibits different electrochemical behaviors with other coatings. The corrosion initiated at the micro-pores of the coating and the underlying corrosion mechanism is very similar to that of the pitting corrosion.

  16. Effect of Plasma Nitriding and Nitrocarburizing on HVOF-Sprayed Stainless Steel Coatings

    Science.gov (United States)

    Park, Gayoung; Bae, Gyuyeol; Moon, Kyungil; Lee, Changhee

    2013-12-01

    In this work, the effects of plasma nitriding (PN) and nitrocarburizing on HVOF-sprayed stainless steel nitride layers were investigated. 316 (austenitic), 17-4PH (precipitation hardening), and 410 (martensitic) stainless steels were plasma-nitrided and nitrocarburized using a N2 + H2 gas mixture and the gas mixture containing C2H2, respectively, at 550 °C. The results showed that the PN and nitrocarburizing produced a relatively thick nitrided layer consisting of a compound layer and an adjacent nitrogen diffusion layer depending on the crystal structures of the HVOF-sprayed stainless steel coatings. Also, the diffusion depth of nitrogen increased when a small amount of C2H2 (plasma nitrocarburizing process) was added. The PN and nitrocarburizing resulted in not only an increase of the surface hardness, but also improvement of the load bearing capacity of the HVOF-sprayed stainless steel coatings because of the formation of CrN, Fe3N, and Fe4N phases. Also, the plasma-nitrocarburized HVOF-sprayed 410 stainless steel had a superior surface microhardness and load bearing capacity due to the formation of Cr23C6 on the surface.

  17. Phase Composition, Microstructure, and Tribological Property of Plasma-Sprayed TiC-BASED Coating

    Science.gov (United States)

    Sun, Shibin; Zou, Zengda; Liu, Xuemei; Shi, Hanchao

    TiC-based wear resistant coating was prepared by plasma spraying using reconstituted composite powders doped with ultra-fine carbide. Phase composition and microstructure of as-sprayed coating were characterized by X-ray diffraction (XRD), scanning electron microscope (SEM) utilizing backscattered imaging mode (BSE), and electron probe micro-analysis. Wear test was performed by using a ring-on-block tester under dry sliding condition. Results show that the coating adheres well to the substrate and no delamination appears. TiC content underwent pronounced reduction because of oxidation, reaction, and physical loss. Reactions between TiC and Mo and probably between dissociated C and Mo lead to the formation of Mo2C. Wear resistance of NiCrMo-TiC coating is about 4-8 times higher than that of substrate under different applied force. This work shed light on the reconstitution of spraying powder doped with ultra-fine reinforce phase particles, and the present results are important for the preparation of nano-doped TiC-based coatings.

  18. Synthesis and characterization of binder-free Cr{sub 3}C{sub 2} coatings on nickel-based alloys for molten fluoride salt corrosion resistance

    Energy Technology Data Exchange (ETDEWEB)

    Brupbacher, Michael C.; Zhang, Dajie [Department of Materials Science and Engineering, The Johns Hopkins University, 3400 North Charles Street, Baltimore, MD 21218 (United States); Buchta, William M. [The Johns Hopkins University Applied Physics Laboratory, 11100 Johns Hopkins Road, Laurel, MD 20723 (United States); Graybeal, Mark L. [U.S. Army Research Laboratory, Aberdeen Proving Ground, MD 21005 (United States); Rhim, Yo-Rhin [The Johns Hopkins University Applied Physics Laboratory, 11100 Johns Hopkins Road, Laurel, MD 20723 (United States); Nagle, Dennis C. [Department of Materials Science and Engineering, The Johns Hopkins University, 3400 North Charles Street, Baltimore, MD 21218 (United States); Spicer, James B., E-mail: spicer@jhu.edu [Department of Materials Science and Engineering, The Johns Hopkins University, 3400 North Charles Street, Baltimore, MD 21218 (United States)

    2015-06-15

    Under various conditions, chromium carbides appear to be relatively stable in the presence of molten fluoride salts and this suggests that their use in corrosion resistant coatings for fluoride salt environments could be beneficial. One method for producing these coatings is the carburization of sprayed Cr coatings using methane-containing gaseous precursors. This process has been investigated for the synthesis of binder-free chromium carbide coatings on nickel-based alloy substrates for molten fluoride salt corrosion resistance. The effects of the carburization process on coating microstructure have been characterized using X-ray diffraction (XRD) and scanning electron microscopy (SEM) in conjunction with energy dispersive spectroscopy (EDS). Both plasma-sprayed and cold-sprayed Cr coatings have been successfully converted to Cr{sub 3}C{sub 2}, with the mechanism of conversion being strongly influenced by the initial porosity in the as-deposited coatings.

  19. Experimental investigation on erosive wear behaviour of plasma spray coated stainless steel

    Science.gov (United States)

    Girisha, K. G.; Sreenivas Rao, K. V.; Anil, K. C.; Sanman, S.

    2017-04-01

    Slurry erosion is an implicit problem in many engineering industrial components such as ore carrying pipelines, slurry pumps and extruders. Even the water turbine blades are subjected to erosive wear when the water contains considerable amount of silt. In the present study, Al2O3-40%TiO2 powder particles of average particle size of 50 micrometer were deposited on EN56B martenistic stainless steel by atmospheric plasma spray technique. Ni/Cr was pre coated to work as bond coat for good adhesion between coating and the substrate material. A coating thickness of 200 micrometer was achieved. Coated and un-coated substrates were subjected to slurry erosion test as per ASTM G-119 standard. Slurry erosion test rig was used to evaluate the erosion properties at room temperature condition by varying the spindle speed. Scanning electron microphotographs were taken before and after the slurry erosion test. Microstructures reveal uniform distribution of coating materials. Eroded surface shows lip, groove, and crater formation and dense coating resulting in less porosity. Micro hardness test was evaluated and reported. EDX analysis confirms the presence of Al, Ti and O2 particles. It was observed that, Al2O3-40%TiO2 coated substrates exhibit superior erosion resistance as compared to un-coated substrates due to higher hardness and less coating porosity.

  20. Corrosion Testing of Thermal Spray Coatings in a Biomass Co-Firing Power Plant

    Directory of Open Access Journals (Sweden)

    Maria Oksa

    2016-11-01

    Full Text Available Large-scale use of biomass and recycled fuel is increasing in energy production due to climate and energy targets. A 40% cut in greenhouse gas emission compared to 1990 levels and at least a 27% share of renewable energy consumption are set in EU Energy Strategy 2030. Burning fuels with high content of corrosive species such as chlorine and heavy metals causes deterioration of boiler components, shortened lifetime, limited availability of a plant and hence higher maintenance and investment costs and lower thermal and economic efficiency. Coatings can be applied to protect the critical boiler components against high temperature corrosion. In this study, five thermal spray coatings were tested in an actual biomass co-firing boiler for 1300 h with a measurement probe. The coatings were analyzed after the exposure by metallographic means and scanning electron microscope/energy-dispersive X-ray spectroscope (SEM/EDX. The deposits formed on the specimens were analyzed by X-ray fluorescence. At 550 °C, the coatings showed excellent corrosion performance compared to reference material ferritic steel T92. At 750 °C, tube material A263 together with NiCr and NiCrTi had the highest corrosion resistance. To conclude, thermal spray coatings can offer substantial corrosion protection in biomass and recycled fuel burning power plants.

  1. Development of spray coated cathodes for RITS-6.

    Energy Technology Data Exchange (ETDEWEB)

    Simpson, Sean; Leckbee, Joshua J.; Miller, Stephen Samuel

    2013-09-01

    This report documents work conducted in FY13 to conduct a feasibility study on thermal spray coated cathodes to be used in the RITS-6 accelerator in an attempt to improve surface uniformity and repeatability. Currently, the cathodes are coated with colloidal silver by means of painting by hand. It is believed that improving the cathode coating process could simplify experimental setup and improve flash x-ray radiographic performance. This report documents the experimental setup and summarizes the results of our feasibility study. Lastly, it describes the path forward and potential challenges that must be overcome in order to improve the process for creating uniform and repeatable silver coatings for cathodes.

  2. The variations in coating properties across a spray pattern

    Energy Technology Data Exchange (ETDEWEB)

    Sexsmith, M.; Troczynski, T. [Univ. of British Columbia, Vancouver, British Columbia (Canada)

    1994-12-31

    The properties of most thermal spray coatings depend on the size and types of flaws in the coating. These flaws are normally caused by particles which escape the optimum part of the flame and are thus processed inadequately. In order to optimize the coating properties by varying process parameters it is necessary to identify the worst flaws and how they are produced by various spray conditions. This project was undertaken to examine how the as deposited properties of individual particles vary within the spray pattern. A Monte Carlo simulation was used to create a database of particles based on measured, average particle properties within the flame. The database could be queried to produce maps of particles of a specified type within the spray pattern. These maps were then related to measurements of coating properties. Novel measurement techniques were developed to enable highly localized measurements. These include, a foil peel test and a microstructure damage test. Microstructural analysis was used to characterize the state of particles arriving at the coating. A comparison was then made between model predictions and measured results and between the different local measurement techniques.

  3. Microstructural and Mechanical Characterization Study of Cr Coated ATF Claddings After Simulated Integral LOCA Test

    Energy Technology Data Exchange (ETDEWEB)

    Park, Dong Jun; Park, Jung Hwan; Jung, Yang Il; Kim, Hyun Gil; Park, Jeong Yong; Koo, Yang Hyun [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2015-10-15

    Accident tolerant fuel (ATF) cladding has been widely studied by several research groups after Fukushima nuclear reactor accident. Oxidation barrier layer coated Zr fuel cladding is one of the most promising candidate concepts owing to its easy process and lower cost for manufacturing and possibility of developing with short term study compared to other ATF concepts. Coated layer on the surface of Zr tube sample was formed by cold spray coating process. Main requirement of these ATF claddings may be high temperature oxidation resistance. Therefore, their oxidation kinetics and mechanisms have been studied at a wide range of temperatures and in various environments. However, just small plate or short tube samples were simply exposed to a high temperature steam environment. In this study, integral loss-of-coolant accident (LOCA) tests simulating real conditions of fuel claddings during accident were conducted using Cr coated ATF cladding sample for a clear understanding of their behavior under accident conditions. Ballooning behavior and microstructural changes of ATF cladding during the LOCA scenarios were studied systematically and mechanical test results are also presented. Cr coated cladding samples have been successfully fabricated by using existing Zr alloy fuel claddings. For comparative study, integral LOCA test was carried out using Cr coated ATF cladding and existing Zr alloy tube sample. Cr coated ATF cladding showed much smaller rupture opening and circumferential elongation compared to Zr alloy sample. Coated Cr layer prevented outer surface oxidation in spite of exposure for 300s at 1200 .deg. C in steam environment.

  4. Plasma Spray-Physical Vapor Deposition (PS-PVD) of Ceramics for Protective Coatings

    Science.gov (United States)

    Harder, Bryan J.; Zhu, Dongming

    2011-01-01

    In order to generate advanced multilayer thermal and environmental protection systems, a new deposition process is needed to bridge the gap between conventional plasma spray, which produces relatively thick coatings on the order of 125-250 microns, and conventional vapor phase processes such as electron beam physical vapor deposition (EB-PVD) which are limited by relatively slow deposition rates, high investment costs, and coating material vapor pressure requirements. The use of Plasma Spray - Physical Vapor Deposition (PS-PVD) processing fills this gap and allows thin (coatings of less than 100 microns to be generated with the flexibility to tailor microstructures by changing processing conditions. Coatings of yttria-stabilized zirconia (YSZ) were applied to NiCrAlY bond coated superalloy substrates using the PS-PVD coater at NASA Glenn Research Center. A design-of-experiments was used to examine the effects of process variables (Ar/He plasma gas ratio, the total plasma gas flow, and the torch current) on chamber pressure and torch power. Coating thickness, phase and microstructure were evaluated for each set of deposition conditions. Low chamber pressures and high power were shown to increase coating thickness and create columnar-like structures. Likewise, high chamber pressures and low power had lower growth rates, but resulted in flatter, more homogeneous layers

  5. Cr-Ni ALLOY ELECTRODEPOSITION AND COMPARISON WITH CONVENTIONAL PURE Cr COATING TECHNIQUE

    Directory of Open Access Journals (Sweden)

    M. Moniruzzaman

    2012-12-01

    Full Text Available Cr coating is widely used as the outer surface of precision parts due to its attractive appearance and superior corrosion resistance properties. It is obtained by electrodeposition via a conventional bath with hexavalent Cr ions. This manufacturing technique has many drawbacks, such as very low efficiency and high operating temperature and it is hazardous to health. In this work, we studied a Cr-Ni alloy deposition technique and compared the alloy coating properties to those with conventional Cr coating. Sequential two-step alloy electrodeposition was also compared. We took varying concentrations of Cr, Ni and complexing agents for the electrodeposition of Cr-Ni alloy and sequential Cr-Ni alloy coating on mild steel. Operating parameters, i.e. current density and temperature, were varied to examine their effects on the coating properties. The coatings thus obtained were characterized by visual observation, corrosion test, microhardness measurement, morphology and chemical analysis. The Cr-Ni alloy coating was found to be more corrosion resistant in 5% NaCl solution and harder than the pure Cr coating obtained by conventional electrodeposition. Toxic gas was produced in a much lower extent in the alloy coating than the conventional Cr coating technique. Again, the two-step Cr-Ni alloy coating was found better in terms of corrosion resistance as well as hardness compared to the Cr-Ni alloy coating. The process was also found to be much more environmentally friendly.

  6. Sea water corrosion behavior of plasma sprayed abradable coatings

    Science.gov (United States)

    Parida, M.; Nanda, S. P.; Mishra, S. C.

    2017-02-01

    Aluminum based abradable coating is used for sealing purpose in compressor casing of aero engines to withstand up to a service temperature of 450°C. Al-BNSiO2 composite coating is deposited using thermal plasma spray technique. Coating thickness measured and porosity of the coating is evaluated.Coating morphology is observed and EDSanalysis is done with SEM (Jeol make). The effect of time on the sea water corrosion behavior of the coating is evaluated. It is observed that, there is a sharp increase in weight gain of the coating up to six weeks of immersion. This behavior is attributed to the adsorption/deposition of other elements/reactions taking place during interaction with sea water.

  7. The Tribological Performance of Hardfaced/ Thermal Sprayed Coatings for Increasing the Wear Resistance of Ventilation Mill Working Parts

    Directory of Open Access Journals (Sweden)

    A. Vencl

    2015-09-01

    Full Text Available During the coal pulverizing, the working parts of the ventilation mill are being worn by the sand particles. For this reason, the working parts are usually protected with materials resistant to wear (hardfaced/thermal sprayed coatings. The aim of this study was to evaluate the tribological performance of four different types of coatings as candidates for wear protection of the mill’s working parts. The coatings were produced by using the filler materials with the following nominal chemical composition: NiFeBSi-WC, NiCrBSiC, FeCrCTiSi, and FeCrNiCSiBMn, and by using the plasma arc welding and flame and electric arc spraying processes. The results showed that Ni-based coatings exhibited higher wear resistance than Fe-based coatings. The highest wear resistance showed coating produced by using the NiFeBSi-WC filler material and plasma transferred arc welding deposition process. The hardness was not the only characteristic that affected the wear resistance. In this context, the wear rate of NiFeBSi-WC coating was not in correlation with its hardness, in contrast to other coatings. The different wear performance of NiFeBSi-WC coating was attributed to the different type and morphological features of the reinforcing particles (WC.

  8. Structure and corrosion properties of PVD Cr-N coatings

    CERN Document Server

    Liu, C; Ziegele, H; Leyland, A; Matthews, A

    2002-01-01

    PVD Cr-N coatings produced by physical vapor deposition (PVD) are increasingly used for mechanical and tribological applications in various industrial sectors. These coatings are particularly attractive for their excellent corrosion resistance, which further enhances the lifetime and service quality of coated components. PVD Cr-N coated steels in an aqueous solution are usually corroded by galvanic attack via through-coating 'permeable' defects (e.g., pores). Therefore, the corrosion performance of Cr-N coated steel is determined by a number of variables of the coating properties and corrosive environment. These variables include: (i) surface continuity and uniformity; (ii) through-coating porosity; (iii) film density and chemical stability; (iv) growth stresses; (v) interfacial and intermediate layers; (vi) coating thickness; (vii) coating composition; and (viii) substrate properties. In this article, PVD Cr-N coatings were prepared, by electron-beam PVD and sputter deposition, with different compositions, t...

  9. Plasma-sprayed ceramic coatings for protection against molten metal.

    Energy Technology Data Exchange (ETDEWEB)

    Hollis, K. J. (Kendall J.); Peters, M. I. (Maria I.); Bartram, B. D. (Brian D.)

    2002-01-01

    Molten metal environments pose a special demand on materials due to the high temperature corrosion effects and thermal expansion mismatch induced stress effects. A solution that has been successfully employed is the use of a base material for the mechanical strength and a coating material for the chemical compatibility with the molten metal. The work described here used such an approach coating tungsten rods with aluminum oxide, yttria-stabilized zirconia, yttrium oxide, and erbium oxide deposited by atmospheric plasma spraying. The ceramic materials were deposited under varying conditions to produce different structures. Measurement of particle characteristics was performed to correlate to material properties. The coatings were tested in a thermal cycling environment to simulate the metal melting cycle expected in service. Results of the testing indicate the effect of material composition and spray conditions on the thermal cycle crack resistance of the coatings.

  10. Spray coating apparatus having a rotatable workpiece holder

    Science.gov (United States)

    Smith, M.; Katvala, V. W.; Porter, E. E. (Inventor)

    1982-01-01

    A spray coating apparatus is provided for rotating a workpiece relative to a spray station to obtain a uniform coating of the workpiece. In a typical example, the workpiece comprises a ceramic tile which is to be coated with a ceramic coating and the tile is to be used as a reusable component of the thermal protection system for a space shuttle. The apparatus for rotating the workpiece includes a base support having a first rotatable stage for rotation in the horizontal plane and a second rotatable stage for rotation in a second plane inclined at an angle, such as 45 degrees, to the horizontal plane and the workpiece is supported on this second stage. Thus the workpiece is rotatable in both of two planes of rotation.

  11. Solid particle erosion of plasma sprayed ceramic coatings

    Directory of Open Access Journals (Sweden)

    Branco José Roberto Tavares

    2004-01-01

    Full Text Available Thermal spraying allows the production of overlay protective coatings of a great variety of materials, almost without limitations as to its components, phases and constituents on a range of substrates. Wear and corrosion resistant coatings account for significant utilization of thermal spray processes. Besides being a means to evaluate the coating tribological performance, erosion testing allows also an assessment of the coating toughness and adhesion. Nevertheless, the relationship between the erosion behavior of thermal sprayed coatings and its microstructural features is not satisfactorily understood yet. This paper examines room temperature solid particle erosion of zirconia and alumina-based ceramic coatings, with different levels of porosity and varying microstrucutre and mechanical properties. The erosion tests were carried out by a stream of alumina particles with an average size of 50 µm at 70 m/s, carried by an air jet with impingement angle 90°. The results indicate that current erosion models based on hardness alone cannot account for experimental results, and, that there is a strong relationship between the erosion rate and the porosity.

  12. Spray coating of superhydrophobic and angle-independent coloured films.

    Science.gov (United States)

    Ge, Dengteng; Yang, Lili; Wu, Gaoxiang; Yang, Shu

    2014-03-07

    Angle-independent coloured films with superhydrophobicity were fabricated from quasi-amorphous arrays of monodispersed fluorinated silica nanoparticles via one-step spray coating. The film exhibited a high contact angle (>150°) and a low roll-off angle (~2°) and the colour could be tuned to blue, green and moccasin by varying the size of the nanoparticles.

  13. Stress analysis of thermal sprayed coatings using a semi-destructive hole-drilling strain gauge method

    Energy Technology Data Exchange (ETDEWEB)

    Dolhof, V.; Musil, J. [Skoda Research, Ltd., Pizen (Czech Republic); Cepera, M.; Zeman, J. [Military Technical Inst. of Protection, Brno (Czech Republic)

    1995-12-31

    Residual stress is an important parameter in coating technology since it often relates to the maximum coating thickness which can be deposited without spallation, and this applies to coatings produced by different thermal spray and thin film technologies. Indeed, the mechanisms by which residual stress is built up or locked into a coating depends markedly on the deposition process and coating structure (growth structure, phase composition) in the same way too. Methods for determining residual stresses in materials include both destructive and non-destructive methods. This contribution describes semi-destructive hole-drilling strain gauge method modified for measurement of residual stresses in thermal sprayed coatings. This method of stress analysis was used for determination of stress levels in thermal sprayed WC-17% Co coatings onto 13% Cr steel substrates. Results show that deposition conditions and final coating structure influence directly the residual stress level in the coatings. It is proved that semi-destructive hole-tube drilling measurement is effective reproducible method of coating stress analysis and good solution for optimization of deposition process.

  14. Characterization and solderability of cold sprayed Sn-Cu coatings on Al and Cu substrates

    OpenAIRE

    Li, J.F.; Agyakwa, P.A.; Johnson, C. M.; Zhang, D.; Hussain, Tanvir; McCartney, D. G.

    2010-01-01

    Cold sprayed Sn-Cu coatings approximately 40 and 25 μm in average thickness were deposited on aluminium and direct bonded copper (DBC) substrates respectively. Both a statistical analysis of coating thickness and a roughness analysis of the coating/substrate interface and the coating surface were carried out for the as-sprayed coatings using scanning electron microscope images. The results obtained can be related to substrate types and spraying conditions. Tin oxide on the surfaces of the as-...

  15. Single impact erosion studies of Cr{sub 3}C{sub 2}-NiCr coating: the role of microstructure variation

    Energy Technology Data Exchange (ETDEWEB)

    Matthews, S.; Hyland, M.; James, B. [Massey Univ., Auckland (New Zealand)

    2008-07-01

    Cr{sub 3}C{sub 2}-NiCr thermal spray coatings have been extensively applied to mitigate erosion in high temperature applications such as aircraft and power generation turbines. Much laboratory based erosion research has been conducted under ambient temperature and mild erosion conditions. However, little has been presented about the coating response under the high temperature, high velocity erosion conditions typically experienced in industrial applications. This work presents the mechanisms of high velocity erosion based on experiments conducted under realistic service conditions. Single impact studies were carried out on a range of Cr{sub 3}C{sub 2}-NiCr coatings to assess the variation in erosion mechanism with phase degradation and starting powder morphology. Comparisons were made between the coating response in the as-sprayed state and after long-term heat treatment to determine how the erosion response changes as a function of exposure time in-service. Erosion of the as-sprayed coatings was heavily influenced by splat boundary related mass loss mechanisms. This was accentuated by in-flight carbide dissolution in the coatings based on agglomerated/sintered powders. Heat treatment led to splat sintering and a transition in the erosion response towards more microstructural based erosion mechanisms. The variation in erosion response as a function of microstructural development with heat treatment and starting powder type is presented. (orig.)

  16. Computational homogenisation for thermoviscoplasticity: application to thermally sprayed coatings

    Science.gov (United States)

    Berthelsen, Rolf; Denzer, Ralf; Oppermann, Philip; Menzel, Andreas

    2017-07-01

    Metal forming processes require wear-resistant tool surfaces in order to ensure a long life cycle of the expensive tools together with a constant high quality of the produced components. Thermal spraying is a relatively widely applied coating technique for the deposit of wear protection coatings. During these coating processes, heterogeneous coatings are deployed at high temperatures followed by quenching where residual stresses occur which strongly influence the performance of the coated tools. The objective of this article is to discuss and apply a thermo-mechanically coupled simulation framework which captures the heterogeneity of the deposited coating material. Therefore, a two-scale finite element framework for the solution of nonlinear thermo-mechanically coupled problems is elaborated and applied to the simulation of thermoviscoplastic material behaviour including nonlinear thermal softening in a geometrically linearised setting. The finite element framework and material model is demonstrated by means of numerical examples.

  17. An Assessment of the Residual Stresses in Low Pressure Plasma Sprayed Coatings on an Advanced Copper Alloy

    Science.gov (United States)

    Raj, S. V.; Ghosn, L. J.; Agarwal, A.; Lachtrupp, T. P.

    2002-01-01

    Modeling studies were conducted on low pressure plasma sprayed (LPPS) NiAl top coat applied to an advanced Cu-8(at.%)Cr-4%Nb alloy (GRCop-84) substrate using Ni as a bond coat. A thermal analysis suggested that the NiAl and Ni top and bond coats, respectively, would provide adequate thermal protection to the GRCop-84 substrate in a rocket engine operating under high heat flux conditions. Residual stress measurements were conducted at different depths from the free surface on coated and uncoated GRCop-84 specimens by x-ray diffraction. These data are compared with theoretically estimated values assessed by a finite element analysis simulating the development of these stresses as the coated substrate cools down from the plasma spraying temperature to room temperature.

  18. Evaluation of the behavior of shrouded plasma spray coatings in the platen superheater of coal-fired boilers

    Science.gov (United States)

    Sidhu, Buta Singh; Prakash, S.

    2006-06-01

    Nickel- and cobalt-based coatings were formulated by a shrouded plasma spray process on boiler tube steels, namely, ASTM-SA210-grade A1 (GrA1), ASTM-SA213-T-11 (T11), and ASTM-SA213-T-22 (T22). The Ni-22Cr-10Al-1Y alloy powder was sprayed as a bond in each case before the final coating. The degradation behavior of the bared and coated steels was studied in the platen superheater of the coal-fired boiler. The samples were inserted through the soot blower dummy points with the help of stainless steel wires. The coatings were found to be effective in increasing resistance to degradation in the given boiler environment. The maximum protection was observed in the case of Stellite-6 (St-6) coating.

  19. Evaluation of the behavior of shrouded plasma spray coatings in the platen superheater of coal-fired boilers

    Energy Technology Data Exchange (ETDEWEB)

    Sidhu, B.S.; Prakash, S. [GZS College of Engineering & Technology, Bathinda (India). Dept. of Mechanical Engineering

    2006-06-15

    Nickel- and cobalt-based coatings were formulated by a shrouded plasma spray process on boiler tube steels, namely, ASTM-SA210-grade A1 (GrA1), ASTM-SA213-T-11 (T11), and ASTM-SA213-T-22 (T22). The Ni-22Cr-10A1-1Y alloy powder was sprayed as a bond in each case before the final coating. The degradation behavior of the bared and coated steels was studied in the platen superheater of the coal-fired boiler. The samples were inserted through the soot blower dummy points with the help of stainless steel wires. The coatings were found to be effective in increasing resistance to degradation in the given boiler environment. The maximum protection was observed in the case of Stellite-6 (St-6) coating.

  20. Interface bonding of NiCrAlY coating on laser modified H13 tool steel surface

    Science.gov (United States)

    Reza, M. S.; Aqida, S. N.; Ismail, I.

    2016-06-01

    Bonding strength of thermal spray coatings depends on the interfacial adhesion between bond coat and substrate material. In this paper, NiCrAlY (Ni-164/211 Ni22 %Cr10 %Al1.0 %Y) coatings were developed on laser modified H13 tool steel surface using atmospheric plasma spray (APS). Different laser peak power, P p, and duty cycle, DC, were investigated in order to improve the mechanical properties of H13 tool steel surface. The APS spraying parameters setting for coatings were set constant. The coating microstructure near the interface was analyzed using IM7000 inverted optical microscope. Interface bonding of NiCrAlY was investigated by interfacial indentation test (IIT) method using MMT-X7 Matsuzawa Hardness Tester Machine with Vickers indenter. Diffusion of atoms along NiCrAlY coating, laser modified and substrate layers was investigated by energy-dispersive X-ray spectroscopy (EDXS) using Hitachi Tabletop Microscope TM3030 Plus. Based on IIT method results, average interfacial toughness, K avg, for reference sample was 2.15 MPa m1/2 compared to sample L1 range of K avg from 6.02 to 6.96 MPa m1/2 and sample L2 range of K avg from 2.47 to 3.46 MPa m1/2. Hence, according to K avg, sample L1 has the highest interface bonding and is being laser modified at lower laser peak power, P p, and higher duty cycle, DC, prior to coating. The EDXS analysis indicated the presence of Fe in the NiCrAlY coating layer and increased Ni and Cr composition in the laser modified layer. Atomic diffusion occurred in both coating and laser modified layers involved in Fe, Ni and Cr elements. These findings introduce enhancement of coating system by substrate surface modification to allow atomic diffusion.

  1. Anti-icing Behavior of Thermally Sprayed Polymer Coatings

    Science.gov (United States)

    Koivuluoto, Heli; Stenroos, Christian; Kylmälahti, Mikko; Apostol, Marian; Kiilakoski, Jarkko; Vuoristo, Petri

    2017-01-01

    Surface engineering shows an increasing potential to provide a sustainable approach to icing problems. Currently, several passive anti-ice properties adoptable to coatings are known, but further research is required to proceed for practical applications. This is due to the fact that icing reduces safety, operational tempo, productivity and reliability of logistics, industry and infrastructure. An icing wind tunnel and a centrifugal ice adhesion test equipment can be used to evaluate and develop anti-icing and icephobic coatings for a potential use in various arctic environments, e.g., in wind power generation, oil drilling, mining and logistic industries. The present study deals with evaluation of icing properties of flame-sprayed polyethylene (PE)-based polymer coatings. In the laboratory-scale icing tests, thermally sprayed polymer coatings showed low ice adhesion compared with metals such as aluminum and stainless steel. The ice adhesion strength of the flame-sprayed PE coating was found to have approximately seven times lower ice adhesion values compared with metallic aluminum, indicating a very promising anti-icing behavior.

  2. Anti-icing Behavior of Thermally Sprayed Polymer Coatings

    Science.gov (United States)

    Koivuluoto, Heli; Stenroos, Christian; Kylmälahti, Mikko; Apostol, Marian; Kiilakoski, Jarkko; Vuoristo, Petri

    2016-12-01

    Surface engineering shows an increasing potential to provide a sustainable approach to icing problems. Currently, several passive anti-ice properties adoptable to coatings are known, but further research is required to proceed for practical applications. This is due to the fact that icing reduces safety, operational tempo, productivity and reliability of logistics, industry and infrastructure. An icing wind tunnel and a centrifugal ice adhesion test equipment can be used to evaluate and develop anti-icing and icephobic coatings for a potential use in various arctic environments, e.g., in wind power generation, oil drilling, mining and logistic industries. The present study deals with evaluation of icing properties of flame-sprayed polyethylene (PE)-based polymer coatings. In the laboratory-scale icing tests, thermally sprayed polymer coatings showed low ice adhesion compared with metals such as aluminum and stainless steel. The ice adhesion strength of the flame-sprayed PE coating was found to have approximately seven times lower ice adhesion values compared with metallic aluminum, indicating a very promising anti-icing behavior.

  3. Corrosion Performance of Laser Posttreated Cold Sprayed Titanium Coatings

    Science.gov (United States)

    Marrocco, T.; Hussain, T.; McCartney, D. G.; Shipway, P. H.

    2011-06-01

    The recent development of cold spray technology has made possible the deposition of highly reactive, oxygen sensitive materials, such as titanium, without significant chemical reaction of the powder, modification of particle microstructure and with minimal heating of the substrate. However, the presence of interconnected pathways (microscale porosity) within the deposit limits the performance of the metallic coating as an effective barrier to corrosion and substrate attack by corrosive media is usually inevitable. The aim of the present study was to investigate the effects of processing, including a postspray laser treatment, on the deposit microstructure and corrosion behavior. Commercially pure titanium (CP Ti) was deposited onto a carbon steel substrate, using a commercial cold spray system (CGTTM Kinetiks® 4000) with preheated nitrogen as both the main process gas and the powder carrier gas. Selected coatings were given a surface melting treatment using a commercial 2 kW CO2 laser (505 Trumpf DMD). The effect of postdeposition laser treatment on corrosion behavior was analyzed in terms of pore structure evolution and microstructural changes. Optical microscopy, scanning electron microscopy, and x-ray diffraction were employed to examine the microstructural characteristics of the coatings. Their corrosion performance was investigated using electrochemical methods in 3.5 wt.% NaCl (ASTM G5-94 (2004)). As-sprayed titanium coatings could not provide favorable protection to the carbon steel substrate in the aerated NaCl solution, whereas the coatings with laser-treated surfaces provided barrier-like properties.

  4. Study on the subsonic speed flame spraying coating of hydroxyapatite

    Institute of Scientific and Technical Information of China (English)

    2003-01-01

    A new method of preparation of biomaterial composite coating by the technique of subsonic thermal sprayingwas discussed in this paper. Ti6A14V and pure Ti were chosen as substrate and sublayer material respectively and the work-ing layer was sprayed with biomaterial hydroxyapatite (HAP), forming the composite coating. The experiments of heatshock and tensile strength showed that the bonding strength between coating and substrate is almost as same as that of spe-cimen in which Ni/Al powder was adopted as sublayer. The phases of TiN, TiO2, and Ti2O3 were formed in the sublayer,which are free of toxic and have no side effects. The powder of working layer HAP was decomposed partly during spraying,but it can be solved by later treatment.

  5. Innovation in the Process of Thermal Spraying Coatings

    Directory of Open Access Journals (Sweden)

    Szczucka-Lasota B.

    2016-09-01

    Full Text Available In this paper, the hybrid method connects the ultrasonic spraying method with a injector of complex cooling micro-jet system is presented. The use of properly constructed injector allows for local and selective cooling of the coating structure immediately after spraying process. The construction of injector is the subject of patent in Polen. The presented new technology gives practical possibility of control of coatings structure. This is the kind of positive feedback between the technology process and obtained product (the quality of the process increases the quality of the final product. The initial experimental investigations, presented in this paper, show, that the obtained coatings structure is: fine-dispersion of the grain, with a lower porosity, good compactness and adhesion to the substrate.

  6. Hierarchical Formation of Intrasplat Cracks in Thermal Spray Ceramic Coatings

    Science.gov (United States)

    Chen, Lin; Yang, Guan-Jun; Li, Cheng-Xin; Li, Chang-Jiu

    2016-06-01

    Intrasplat cracks, an essential feature of thermally sprayed ceramic coatings, play important roles in determining coating properties. However, final intrasplat crack patterns are always considered to be disordered and irregular, resulting from random cracking during splat cooling, since the detailed formation process of intrasplat cracks has scarcely been considered. In the present study, the primary formation mechanism for intrasplat cracking was explored based on both experimental observations and mechanical analysis. The results show that the intrasplat crack pattern in thermally sprayed ceramic splats presents a hierarchical structure with four sides and six neighbors, indicating that intrasplat crack patterns arise from successive domain divisions due to sequential cracking during splat cooling. The driving forces for intrasplat cracking are discussed, and the experimental data quantitatively agree well with theoretical results. This will provide insight for further coating structure designs and tailoring by tuning of intrasplat cracks.

  7. Standard guide for metallographic preparation of thermal sprayed coatings

    CERN Document Server

    American Society for Testing and Materials. Philadelphia

    2003-01-01

    1.1 This guide covers recommendations for sectioning, cleaning, mounting, grinding, and polishing to reveal the microstructural features of thermal sprayed coatings (TSCs) and the substrates to which they are applied when examined microscopically. Because of the diversity of available equipment, the wide variety of coating and substrate combinations, and the sensitivity of these specimens to preparation technique, the existence of a series of recommended methods for metallographic preparation of thermal sprayed coating specimens is helpful. Adherence to this guide will provide practitioners with consistent and reproducible results. Additional information concerning standard practices for metallographic preparation can be found in Practice E 3. 1.2 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitatio...

  8. Improvement in the properties of plasma-sprayed metallic, alloy and ceramic coatings using dry-ice blasting

    Science.gov (United States)

    Dong, Shujuan; Song, Bo; Hansz, Bernard; Liao, Hanlin; Coddet, Christian

    2011-10-01

    Dry-ice blasting, as an environmental-friendly method, was introduced into atmospheric plasma spraying for improving properties of metallic, alloy and ceramic coatings. The deposited coatings were then compared with coatings plasma-sprayed using conventional air cooling in terms of microstructure, temperature, oxidation, porosity, residual stress and adhesion. It was found that a denser steel or CoNiCrAlY alloy coating with a lower content of oxide can be achieved with the application of dry-ice blasting during the plasma spraying. In addition, the adhesive strength of Al 2O 3 coating deposited with dry-ice blasting exceeded 60 MPa, which was nearly increased by 30% compared with that of the coating deposited with conventional air cooling. The improvement in properties of plasma-sprayed metallic, alloy and ceramic coatings caused by dry-ice blasting was attributed to the decrease of annulus-ringed disk like splats, the better cooling efficiency of dry-ice pellets and even the mechanical effect of dry-ice impact.

  9. Plasma sprayed rutile titania-nanosilver antibacterial coatings

    Science.gov (United States)

    Gao, Jinjin; Zhao, Chengjian; Zhou, Jingfang; Li, Chunxia; Shao, Yiran; Shi, Chao; Zhu, Yingchun

    2015-11-01

    Rutile titania (TiO2) coatings have superior mechanical properties and excellent stability that make them preferential candidates for various applications. In order to prevent infection arising from bacteria, significant efforts have been focused on antibacterial TiO2 coatings. In the study, titania-nanosilver (TiO2/Ag) coatings with five different kinds of weight percentages of silver nanoparticles (AgNPs) were prepared by plasma spray. The feedstock powders, which had a composition of rutile TiO2 powders containing 1-10,000 ppm AgNPs, were double sintered and deposited on stainless steel substrates with optimized spraying parameters. X-Ray diffraction and scanning electron microscopy were used to analysize the phase composition and surface morphology of TiO2/Ag powders and coatings. Escherichia coli (E. coli) and Staphylococcus aureus (S. aureus) were employed to examine the antibacterial activity of the as-prepared coatings by bacterial counting method. The results showed that silver existed homogeneously in the TiO2/Ag coatings and no crystalline changed happened in the TiO2 structure. The reduction ratios on the TiO2/Ag coatings with 10 ppm AgNPs were as high as 94.8% and 95.6% for E. coli and S. aureus, respectively, and the TiO2/Ag coatings with 100-1000 ppm AgNPs exhibited 100% bactericidal activity against E. coli and S. aureus, which indicated the TiO2/Ag coatings with more than 10 ppm AgNPs had strong antibacterial activity. Moreover, the main factors influencing the antibacterial properties of TiO2/Ag coatings were discussed with grain size and the content of silver as well as the microstructure of the coatings.

  10. Multi-source/component spray coating for polymer solar cells.

    Science.gov (United States)

    Chen, Li-Min; Hong, Ziruo; Kwan, Wei Lek; Lu, Cheng-Hsueh; Lai, Yi-Feng; Lei, Bao; Liu, Chuan-Pu; Yang, Yang

    2010-08-24

    A multi-source/component spray coating process to fabricate the photoactive layers in polymer solar cells is demonstrated. Well-defined domains consisting of polymer:fullerene heterojunctions are constructed in ambient conditions using an alternating spray deposition method. This approach preserves the integrity of the layer morphology while forming an interpenetrating donor (D)/acceptor (A) network to facilitate charge transport. The formation of multi-component films without the prerequisite of a common solvent overcomes the limitations in conventional solution processes for polymer solar cells and enables us to process a wide spectrum of materials. Polymer solar cells based on poly(3-hexylthiophene):[6,6]-phenyl C(61) butyric acid methyl ester spray-coated using this alternating deposition method deliver a power conversion efficiency of 2.8%, which is comparable to their blend solution counterparts. More importantly, this approach offers the versatility to independently select the optimal solvents for the donor and acceptor materials that will deliver well-ordered nanodomains. This method also allows the direct stacking of multiple photoactive polymers with controllable absorption in a tandem structure even without an interconnecting junction layer. The introduction of multiple photoactive materials through multisource/component spray coating offers structural flexibility and tenability of the photoresponse for future polymer solar cell applications.

  11. Monitoring Delamination of Plasma-Sprayed Thermal Barrier Coatings by Reflectance-Enhanced Luminescence

    Science.gov (United States)

    Eldridge, Jeffrey I.; Bencic, Timothy J.

    2006-01-01

    Highly scattering plasma-sprayed thermal barrier coatings (TBCs) present a challenge for optical diagnostic methods to monitor TBC delamination because scattering attenuates light transmitted through the TBC and usually degrades contrast between attached and delaminated regions of the TBC. This paper presents a new approach where reflectance-enhanced luminescence from a luminescent sublayer incorporated along the bottom of the TBC is used to identify regions of TBC delamination. Because of the higher survival rate of luminescence reflecting off the back surface of a delaminated TBC, the strong scattering exhibited by plasma-sprayed TBCs actually accentuates contrast between attached and delaminated regions by making it more likely that multiple reflections of luminescence off the back surface occur before exiting the top surface of the TBC. A freestanding coating containing sections designed to model an attached or delaminated TBC was prepared by depositing a luminescent Eu-doped or Er-doped yttria-stabilized zirconia (YSZ) luminescent layer below a plasma-sprayed undoped YSZ layer and utilizing a NiCr backing layer to represent an attached substrate. For specimens with a Eu-doped YSZ luminescent sublayer, luminescence intensity maps showed excellent contrast between unbacked and NiCr-backed sections even at a plasma-sprayed overlayer thickness of 300 m. Discernable contrast between unbacked and NiCr-backed sections was not observed for specimens with a Er-doped YSZ luminescent sublayer because luminescence from Er impurities in the undoped YSZ layer overwhelmed luminescence originating form the Er-doped YSZ sublayer.

  12. Preparation and properties of HA coating hydrothermally synthesized from plasma sprayed CaHPO4 coating

    Institute of Scientific and Technical Information of China (English)

    FU Tao; HAN Yong; ZHANG Yu-mei; XU Ke-wei

    2001-01-01

    @@ INTRODUCTION Hydroxyapatite (HA) biocoatings can form osseointegration at a shorter time than metallic implants, and plasma sprayed (PS) HA coating has received the widest studies and is now used clinically. However, due to the high temperature of plasma flame, soluble impurity phases and amorphous calcium phosphate were contained which declined the bonding strength of the coating, and spoiled the excellent biological properties of HA.

  13. Preparation of thermal barrier coatings by ultrasonic plasma spraying

    Institute of Scientific and Technical Information of China (English)

    WEN Xiong-wei; LI Lu-ming; ZHANG Hua-tang; HAO Hong-wei; LU Zhi-qing

    2004-01-01

    Modulated plasma arc not only can heat the powder, but also can excite ultrasonic of different frequencies and different powers. The principles and characters of the plasma arc-excited ultrasonic were described, and the ultrasonic plasma spraying was compared with normal plasma spraying. Zirconia thermal barrier coatings (TBCs) were fabricated with two kinds of method. The TBCs were studied by the optical microscope observation, SEM observation and bonding strength experiment. The results show that suitable ultrasonic changes the performance and microstructure of TBCs in evidence. And the mechanism of ultrasonic influencing the TBCs was also discussed.

  14. Design and optimization of coating structure for the thermal barrier coatings fabricated by atmospheric plasma spraying via finite element method

    Directory of Open Access Journals (Sweden)

    L. Wang

    2014-06-01

    Full Text Available The first prerequisite for fabricating the thermal barrier coatings (TBCs with excellent performance is to find an optimized coating structure with high thermal insulation effect and low residual stress. This paper discusses the design and optimization of a suitable coating structure for the TBCs prepared by atmospheric plasma spraying (APS using the finite element method. The design and optimization processes comply with the rules step by step, as the structure develops from a simple to a complex one. The research results indicate that the suitable thicknesses of the bond-coating and top-coating are 60–120 μm and 300–420 μm, respectively, for the single ceramic layer YSZ/NiCoCrAlY APS-TBC. The embedded interlayer (50 wt.%YSZ + 50 wt.%NiCoCrAlY will further reduce the residual stress without sacrificing the thermal insulation effect. The double ceramic layer was further considered which was based on the single ceramic layer TBC. The embedded interlayer and the upper additional ceramic layer will have a best match between the low residual stress and high thermal insulation effect. Finally, the optimized coating structure was obtained, i.e., the La2Ce2O7(LC/YSZ/Interlayer/NiCoCrAlY coating structure with appropriate layer thickness is the best choice. The effective thermal conductivity of this optimized LC/YSZ/IL/BL TBC is 13.2% lower than that of the typical single ceramic layer YSZ/BL TBC.

  15. Sprayed and Spin-Coated Multilayer Antireflection Coating Films for Nonvacuum Processed Crystalline Silicon Solar Cells

    OpenAIRE

    Abdullah Uzum; Masashi Kuriyama; Hiroyuki Kanda; Yutaka Kimura; Kenji Tanimoto; Hidehito Fukui; Taichiro Izumi; Tomitaro Harada; Seigo Ito

    2017-01-01

    Using the simple and cost-effective methods, spin-coated ZrO2-polymer composite/spray-deposited TiO2-compact multilayer antireflection coating film was introduced. With a single TiO2-compact film on the surface of a crystalline silicon wafer, 5.3% average reflectance (the reflectance average between the wavelengths of 300 nm and 1100 nm) was observed. Reflectance decreased further down to 3.3% after forming spin-coated ZrO2 on the spray-deposited TiO2-compact film. Silicon solar cells were fa...

  16. Anisotropic Thermal Diffusivities of Plasma-Sprayed Thermal Barrier Coatings

    Science.gov (United States)

    Akoshima, Megumi; Takahashi, Satoru

    2017-09-01

    Thermal barrier coatings (TBCs) are used to shield the blades of gas turbines from heat and wear. There is a pressing need to evaluate the thermal conductivity of TBCs in the thermal design of advanced gas turbines with high energy efficiency. These TBCs consist of a ceramic-based top coat and a bond coat on a superalloy substrate. Usually, the focus is on the thermal conductivity in the thickness direction of the TBC because heat tends to diffuse from the surface of the top coat to the substrate. However, the in-plane thermal conductivity is also important in the thermal design of gas turbines because the temperature distribution within the turbine cannot be ignored. Accordingly, a method is developed in this study for measuring the in-plane thermal diffusivity of the top coat. Yttria-stabilized zirconia top coats are prepared by thermal spraying under different conditions. The in-plane and cross-plane thermal diffusivities of the top coats are measured by the flash method to investigate the anisotropy of thermal conduction in a TBC. It is found that the in-plane thermal diffusivity is higher than the cross-plane one for each top coat and that the top coats have significantly anisotropic thermal diffusivity. The cross-sectional and in-plane microstructures of the top coats are observed, from which their porosities are evaluated. The thermal diffusivity and its anisotropy are discussed in detail in relation to microstructure and porosity.

  17. Plasma sprayed rutile titania-nanosilver antibacterial coatings

    Energy Technology Data Exchange (ETDEWEB)

    Gao, Jinjin [Key Lab of Inorganic Coating Materials, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050 (China); Zhao, Chengjian [National Key Laboratory of Human Factors Engineering, Department of ECLSS, China Astronaut Researching and Training Center, Beijing, 100094 (China); Zhou, Jingfang [Ian Wark Research Institute, University of South Australia, Mawson Lakes Campus, Mawson Lakes, SA, 5095 (Australia); Li, Chunxia [National Key Laboratory of Human Factors Engineering, Department of ECLSS, China Astronaut Researching and Training Center, Beijing, 100094 (China); Shao, Yiran; Shi, Chao [Key Lab of Inorganic Coating Materials, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050 (China); Zhu, Yingchun, E-mail: yzhu@mail.sic.ac.cn [Key Lab of Inorganic Coating Materials, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050 (China)

    2015-11-15

    Graphical abstract: - Highlights: • TiO{sub 2}/Ag feedstock powders containing 1–10,000 ppm silver nanoparticles were double sintered and deposited by plasma spray. • TiO{sub 2}/Ag coatings were composed of pure rutile phase and homogeneously-distributed metallic silver. • TiO{sub 2}/Ag coatings with more than 10 ppm silver nanoparticles exhibited strong antibacterial activity against E. coli and S. aureus. - Abstract: Rutile titania (TiO{sub 2}) coatings have superior mechanical properties and excellent stability that make them preferential candidates for various applications. In order to prevent infection arising from bacteria, significant efforts have been focused on antibacterial TiO{sub 2} coatings. In the study, titania-nanosilver (TiO{sub 2}/Ag) coatings with five different kinds of weight percentages of silver nanoparticles (AgNPs) were prepared by plasma spray. The feedstock powders, which had a composition of rutile TiO{sub 2} powders containing 1–10,000 ppm AgNPs, were double sintered and deposited on stainless steel substrates with optimized spraying parameters. X-Ray diffraction and scanning electron microscopy were used to analysize the phase composition and surface morphology of TiO{sub 2}/Ag powders and coatings. Escherichia coli (E. coli) and Staphylococcus aureus (S. aureus) were employed to examine the antibacterial activity of the as-prepared coatings by bacterial counting method. The results showed that silver existed homogeneously in the TiO{sub 2}/Ag coatings and no crystalline changed happened in the TiO{sub 2} structure. The reduction ratios on the TiO{sub 2}/Ag coatings with 10 ppm AgNPs were as high as 94.8% and 95.6% for E. coli and S. aureus, respectively, and the TiO{sub 2}/Ag coatings with 100–1000 ppm AgNPs exhibited 100% bactericidal activity against E. coli and S. aureus, which indicated the TiO{sub 2}/Ag coatings with more than 10 ppm AgNPs had strong antibacterial activity. Moreover, the main factors influencing the

  18. Factors affecting the microstructural stability and durability of thermal barrier coatings fabricated by air plasma spraying

    Energy Technology Data Exchange (ETDEWEB)

    Helminiak, M.A.; Yanar, N.M.; Pettit, F.S.; Meier, G.H. [National Energy Technology Laboratory, Pittsburgh, PA 15236 (United States); Department of Mechanical Engineering and Materials Science, University of Pittsburgh, 636 Benedum Hall, 3700 O& #x27; Hara Street, Pittsburgh, PA 15261 (United States); Taylor, T.A. [Praxair Surface Technologies, Inc., 1400 Polco Street, Indianapolis, IN 46224 (United States)

    2012-10-15

    The high-temperature behavior of high-purity, low-density (HP-LD) air plasma sprayed (APS) thermal barrier coatings (TBCs) with NiCoCrAlY bond coats deposited by argon-shrouded plasma spraying is described. The high purity yttria-stabilized zirconia resulted in top coats which are highly resistant to sintering and transformation from the metastable tetragonal phase to the equilibrium mixture of monoclinic and cubic phases. The thermal conductivity of the as-processed TBC is low but increases during high temperature exposure even before densification occurs. The porous topcoat microstructure also resulted in good spallation resistance during thermal cycling. The actual failure mechanisms of the APS coatings were found to depend on topcoat thickness, topcoat density, and the thermal cycle frequency. The failure mechanisms are described and the durability of the HP-LD coatings is compared with that of state-of-the-art electron beam physical vapor deposition TBCs. (Copyright copyright 2012 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim)

  19. Crystal coating via spray drying to improve powder tabletability.

    Science.gov (United States)

    Vanhoorne, V; Peeters, E; Van Snick, B; Remon, J P; Vervaet, C

    2014-11-01

    A continuous crystal coating method was developed to improve both flowability and tabletability of powders. The method includes the introduction of solid, dry particles into an atomized spray during spray drying in order to coat and agglomerate individual particles. Paracetamol was used as a model drug as it exhibits poor flowability and high capping tendency upon compaction. The particle size enlargement and flowability were evaluated by the mean median particle size and flow index of the resulting powders. The crystal coating coprocessing method was successful for the production of powders containing 75% paracetamol with excellent tableting properties. However, the extent of agglomeration achieved during coprocessing was limited. Tablets compressed on a rotary tablet press in manual mode showed excellent compression properties without capping tendency. A formulation with 75% paracetamol, 5% PVP and 20% amorphous lactose yielded a tensile strength of 1.9 MPa at a compression pressure of 288 MPa. The friability of tablets compressed at 188 MPa was only 0.6%. The excellent tabletability of this formulation was attributed to the coating of paracetamol crystals with amorphous lactose and PVP through coprocessing and the presence of brittle and plastic components in the formulation. The coprocessing method was also successfully applied for the production of directly compressible lactose showing improved tensile strength and friability in comparison to a spray dried direct compression lactose grade.

  20. Elastoplastic analysis of process induced residual stresses in thermally sprayed coatings

    Science.gov (United States)

    Chen, Yongxiong; Liang, Xiubing; Liu, Yan; Xu, Binshi

    2010-07-01

    The residual stresses induced from thermal spraying process have been extensively investigated in previous studies. However, most of such works were focused on the elastic deformation range. In this paper, an elastoplastic model for predicting the residual stresses in thermally sprayed coatings was developed, in which two main contributions were considered, namely the deposition induced stress and that due to differential thermal contraction between the substrate and coating during cooling. The deposition induced stress was analyzed based on the assumption that the coating is formed layer-by-layer, and then a misfit strain is accommodated within the multilayer structure after the addition of each layer (plastic deformation is induced consequently). From a knowledge of specimen dimensions, processing temperatures, and material properties, residual stress distributions within the structure can be determined by implementing the model with a simple computer program. A case study for the plasma sprayed NiCoCrAlY on Inconel 718 system was performed finally. Besides some similar phenomena observed from the present study as compared with previous elastic model reported in literature, the elastoplastic model also provides some interesting features for prediction of the residual stresses.

  1. Microstructure of Suspension Plasma Spray and Air Plasma Spray Al2O3-ZrO2 Composite Coatings

    Science.gov (United States)

    Chen, Dianying; Jordan, Eric H.; Gell, Maurice

    2009-09-01

    Al2O3-ZrO2 coatings were deposited by the suspension plasma spray (SPS) molecularly mixed amorphous powder and the conventional air plasma spray (APS) Al2O3-ZrO2 crystalline powder. The amorphous powder was produced by heat treatment of molecularly mixed chemical solution precursors below their crystallization temperatures. Phase composition and microstructure of the as-synthesized and heat-treated SPS and APS coatings were characterized by XRD and SEM. XRD analysis shows that the as-sprayed SPS coating is composed of α-Al2O3 and tetragonal ZrO2 phases, while the as-sprayed APS coating consists of tetragonal ZrO2, α-Al2O3, and γ-Al2O3 phases. Microstructure characterization revealed that the Al2O3 and ZrO2 phase distribution in SPS coatings is much more homogeneous than that of APS coatings.

  2. Elastic behaviour of plasma sprayed thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Steinbrech, R.W.; Frahm, J.; Herzog, R.; Schubert, F. [Inst. for Materials and Processes in Energy Systems, Forschungszentrum Juelich GmbH, Juelich (Germany)

    2002-07-01

    The elastic behaviour of air plasma sprayed (APS) thermal barrier coatings (TBCs) of 8 wt.% yttria stabilised zirconia was studied using various mechanical tests with global and local resolution. Results are presented, which reveal the complex relationship between lamellar APS-microstructure and stiffness and illustrate scaling aspects. Also the influence of residual stresses is addressed. The obtained stiffness values for as-sprayed TBCs show a systematic variation between 10 and 100 GPa. Typically results from bending tests of free-standing TBCs are at the low end, whereas results from depth sensitive indentation tests with TBCs bonded to a substrate are found at the high end. When heat treated above 950 C the TBCs exhibit a rapid increase in stiffness which can be attributed to defect healing within the spraying lamellae. Discussion of the results focuses on the implications of a non-uniform stiffness modulus for the mechanical characterisation of thermal barrier systems. (orig.)

  3. Investigation of the Corrosion Behaviors of HVOF-Sprayed Carbide Cernet Coatings in Molten Al-Zn-Si Alloy Bath

    Institute of Scientific and Technical Information of China (English)

    JIANG Zhen-hua; TAN Xing-hai; ZHANG Yue-gang; SUN Jia-shu

    2004-01-01

    In continuous hot-dip galvanization process the corrosion and chemical stability of the sink roll in the galvanizing bath are important problem which effects on the quality and productivity. In order to protect the sink roll the carbide cermet and/or ceramic coatings were deposited on the surface of the sink roll. The WC-, Cr3 C2-cermet coatings were deposited by high velocity oxygen fuel (HVOF) spray, respectively. The coating samples were immersed in molten Zn-alloy containing 50 wt % aluminum at 833 K for 24 hr and 144 hr, respectively. The inter-diffusion and inter-reaction of Zn, Al and elements in coating and corrosion behaviors of these coatings were investigated by XRD, SEM and EPMA etc. The corrosion mechanisms of the carbide cermet coatings and ceramic coatings in molten High Al-Zn-alloy were approached.

  4. High-temperature thermo-mechanical behavior of functionally graded materials produced by plasma sprayed coating: Experimental and modeling results

    Science.gov (United States)

    Choi, Kang Hyun; Kim, Hyun-Su; Park, Chang Hyun; Kim, Gon-Ho; Baik, Kyoung Ho; Lee, Sung Ho; Kim, Taehyung; Kim, Hyoung Seop

    2016-09-01

    Thermal barrier coatings are widely used in aerospace industries to protect exterior surfaces from harsh environments. In this study, functionally graded materials (FGMs) were investigated with the aim to optimize their high temperature resistance and strength characteristics. NiCrAlY bond coats were deposited on Inconel-617 superalloy substrate specimens by the low vacuum plasma spraying technique. Functionally graded Ni-yttria-stabilized zirconia (YSZ) coatings with gradually varying amounts of YSZ (20%-100%) were fabricated from composite powders by vacuum plasma spraying. Heat shield performance tests were conducted using a high- temperature plasma torch. The temperature distributions were measured using thermocouples at the interfaces of the FGM layers during the tests. A model for predicting the temperature at the bond coating-substrate interface was established. The temperature distributions simulated using the finite element method agreed well with the experimental results.

  5. High Power Diode Laser-Treated HP-HVOF and Twin Wire Arc-Sprayed Coatings for Fossil Fuel Power Plants

    Science.gov (United States)

    Mann, B. S.

    2013-08-01

    This article deals with high power diode laser (HPDL) surface modification of twin wire arc-sprayed (TWAS) and high pressure high velocity oxy-fuel (HP-HVOF) coatings to combat solid particle erosion occurring in fossil fuel power plants. To overcome solid particle impact wear above 673 K, Cr3C2-NiCr-, Cr3C2-CoNiCrAlY-, and WC-CrC-Ni-based HVOF coatings are used. WC-CoCr-based HVOF coatings are generally used below 673 K. Twin wire arc (TWA) spraying of Tafa 140 MXC and SHS 7170 cored wires is used for a wide range of applications for a temperature up to 1073 K. Laser surface modification of high chromium stainless steels for steam valve components and LPST blades is carried out regularly. TWA spraying using SHS 7170 cored wire, HP-HVOF coating using WC-CoCr powder, Ti6Al4V alloy, and high chromium stainless steels (X20Cr13, AISI 410, X10CrNiMoV1222, 13Cr4Ni, 17Cr4Ni) were selected in the present study. Using robotically controlled parameters, HPDL surface treatments of TWAS-coated high strength X10CrNiMoV1222 stainless steel and HP-HVOF-coated AISI 410 stainless steel samples were carried out and these were compared with HPDL-treated high chromium stainless steels and titanium alloy for high energy particle impact wear (HEPIW) resistance. The HPDL surface treatment of the coatings has improved the HEPIW resistance manifold. The improvement in HPDL-treated stainless steels and titanium alloys is marginal and it is not comparable with that of HPDL-treated coatings. These coatings were also compared with "as-sprayed" coatings for fracture toughness, microhardness, microstructure, and phase analyses. The HEPIW resistance has a strong relationship with the product of fracture toughness and microhardness of the HPDL-treated HP-HVOF and TWAS SHS 7170 coatings. This development opens up a possibility of using HPDL surface treatments in specialized areas where the problem of HEPIW is very severe. The HEPIW resistance of HPDL-treated high chromium stainless steels and

  6. Analysis on Residual Stresses of Plasma Sprayed NiCrAl/Cr2O3-8%TiO2 Coatings%等离子喷涂NiCrAl/Cr2O3-8%TiO2涂层残余应力模拟分析

    Institute of Scientific and Technical Information of China (English)

    张宝霞; 段忠清

    2010-01-01

    建立了模拟涂层残余应力的数学模型,对等离子喷涂不同厚度NiCrAl/Cr2O3-8%TiO2涂层的残余应力进行了模拟,模拟结果表明:由于涂层与基体的热膨胀系数不匹配等原因,在界面等区域存在严重的应力集中,涂层内部的残余应力水平,随涂层厚度增加而增加,涂层中的径向、轴向、切向应力均为压应力,径向应力是最主要的应力.

  7. Ferromagnetic shadow mask for spray coating of polymer patterns

    DEFF Research Database (Denmark)

    Keller, Stephan Sylvest; Bosco, Filippo; Boisen, Anja

    2013-01-01

    We present the fabrication of a wafer-scale shadow mask with arrays of circular holes with diameters of 150–400 μm. Standard UV photolithography is used to define 700 μm thick SU-8 structures followed by electroplating of nickel and etching of the template. The ferromagnetic properties of the sha...... of the shadow mask allow magnetic clamping to the substrate and spray coating of well defined polymer patterns....

  8. Performance of high-velocity oxyfuel-sprayed coatings on an Fe-based superalloy in Na2SO4-60%V2O5 environment at 900 °C part II: Hot corrosion behavior of the coatings

    Science.gov (United States)

    Sidhu, T. S.; Prakash, S.; Agrawal, R. D.

    2006-02-01

    NiCrBSi, Cr3C2-NiCr, Ni-20Cr, and Stellite-6 coatings were deposited on an Fe-based superalloy by the high-velocity oxyfuel (HVOF) thermal spray process. The hot corrosion behavior of the coatings in an aggressive environment of Na2SO4-60%V2O5 at 900 °C under cyclic conditions was studied. The thermogravimetric technique was used to establish the kinetics of corrosion. X-ray diffraction, scanning electron microscopy/energy-dispersive x-ray and electron probe microanalysis techniques were used to analyze the corrosion products. Hot corrosion resistances of all the coatings were found to be better than the uncoated superalloy. The Ni-20Cr coating was found to be the most protective, followed by Cr3C2-NiCr coatings. The Ni-20Cr coating had reduced the mass gain by 90% of that gained by the uncoated superalloy. The hot corrosion resistance shown by the Cr3C2-NiCr coating was slightly better compared with the NiCrBSi coating; however, both of the coatings performed better than the Stellite-6 coating. The Stellite-6 coating was the least effective among the coatings studied, but it was still successful in decreasing the mass gain to about one fourth compared with the uncoated superalloy. The formation of oxides and spinels of nickel, chromium, or cobalt may be contributing to the development of hot corrosion resistance in the coatings. This article focuses on the hot corrosion behavior of HVOF coatings. The characterization of these coatings has been presented in part I included in this issue.

  9. Methods for coating conduit interior surfaces utilizing a thermal spray gun with extension arm

    Science.gov (United States)

    Moore, Karen A.; Zatorski, Raymond A.

    2007-10-02

    Systems and methods for applying a coating to an interior surface of a conduit. In one embodiment, a spray gun configured to apply a coating is attached to an extension arm which may be inserted into the bore of a pipe. The spray gun may be a thermal spray gun adapted to apply a powder coating. An evacuation system may be used to provide a volume area of reduced air pressure for drawing overspray out of the pipe interior during coating. The extension arm as well as the spray gun may be cooled to maintain a consistent temperature in the system, allowing for more consistent coating.

  10. Ceramic Top Coats of Plasma-Sprayed Thermal Barrier Coatings: Materials, Processes, and Properties

    Science.gov (United States)

    Bakan, Emine; Vaßen, Robert

    2017-08-01

    The ceramic top coat has a major influence on the performance of the thermal barrier coating systems (TBCs). Yttria-partially-stabilized zirconia (YSZ) is the top coat material frequently used, and the major deposition processes of the YSZ top coat are atmospheric plasma spraying and electron beam physical vapor deposition. Recently, also new thermal spray processes such as suspension plasma spraying or plasma spray-physical vapor deposition have been intensively investigated for TBC top coat deposition. These new processes and particularly the different coating microstructures that can be deposited with them will be reviewed in this article. Furthermore, the properties and the intrinsic-extrinsic degradation mechanisms of the YSZ will be discussed. Following the TBC deposition processes and standard YSZ material, alternative ceramic materials such as perovskites and hexaaluminates will be summarized, while properties of pyrochlores with regard to their crystal structure will be discussed more in detail. The merits of the pyrochlores such as good CMAS resistance as well as their weaknesses, e.g., low fracture toughness, processability issues, will be outlined.

  11. Plasma Processes : Plasma sprayed alumina coatings for radiation detector development

    Indian Academy of Sciences (India)

    Mary Alex; V Balagi; K R Prasad; K P Sreekumar; P V Ananthapadmanabhan

    2000-11-01

    Conventional design of radiation detectors uses sintered ceramic insulating modules. The major drawback of these ceramic components is their inherent brittleness. Ion chambers, in which these ceramic spacers are replaced by metallic components with plasma spray coated alumina, have been developed in our Research Centre. These components act as thin spacers that have good mechanical strength as well as high electrical insulation and replace alumina insulators with the same dimensions. As a result, the design of the beam loss monitor ion chamber for CAT could be simplified by coating the outer surface of the HT electrode with alumina. One of the chambers developed for isotope calibrator for brachytherapy gamma sources has its outer aluminium electrode (60 mm dia × 220 mm long) coated with 250 thick alumina (97%) + titania (3%). In view of potential applications in neutron-sensitive ion chambers used in reactor control instrumentation, studies were carried out on alumina 100 to 500 thick coatings on copper, aluminium and SS components. The electrical insulation varied from 108 ohms to 1012 ohms for coating thicknesses above 200 . The porosity in the coating resulted in some fall in electrical insulation due to moisture absorption. An improvement could be achieved by providing the ceramic surface with moisture-repellent silicone oil coating. Irradiation at Apsara reactor core location showed that the coating on aluminium was found to be unaffected after exposure to 1017 nvt fluence.

  12. Microstructural evolution and growth kinetics of thermally grown oxides in plasma sprayed thermal barrier coatings

    Directory of Open Access Journals (Sweden)

    Xiaoju Liu

    2016-02-01

    Full Text Available The formation of thermally grown oxide (TGO during high temperature is a key factor to the degradation of thermal barrier coatings (TBCs applied on hot section components. In the present study both the CoNiCrAlY bond coat and ZrO2-8 wt.% Y2O3 (8YSZ ceramic coat of TBCs were prepared by air plasma spraying (APS. The composition and microstructure of TGO in TBCs were investigated using scanning electron microscopy (SEM, energy dispersive spectroscopy (EDS and X-ray diffraction (XRD analysis. The growth rate of TGO for TBC and pure BC were gained after isothermal oxidation at 1100 °C for various times. The results showed that as-sprayed bond coat consisted of β and γ/γ′phases, β phase reducesd as the oxidation time increased. The TGO comprised α-Al2O3 formed in the first 2 h. CoO, NiO, Cr2O3 and spinel oxides appeared after 20 h of oxidation. Contents of CoO and NiO reduced while that of Cr2O3 and spinel oxides increased in the later oxidation stage. The TGO eventually consisted of a sub-Al2O3 layer with columnar microstructure and the upper porous CS clusters. The TGO growth kinetics for two kinds of samples followed parabolic laws, with oxidation rate constant of 0.344 μm/h0.5 for TBCs and 0.354 μm/h0.5 for pure BCs.

  13. Microstructural evolution and growth kinetics of thermally grown oxides in plasma sprayed thermal barrier coatings

    Institute of Scientific and Technical Information of China (English)

    Xiaoju Liu; Teng Wang; Caicai Li; Zhenhuan Zheng; Qiang Li

    2016-01-01

    The formation of thermally grown oxide (TGO) during high temperature is a key factor to the degradation of thermal barrier coatings (TBCs) applied on hot section components. In the present study both the CoNiCrAlY bond coat and ZrO2-8 wt.% Y2O3 (8YSZ) ceramic coat of TBCs were prepared by air plasma spraying (APS). The composition and microstructure of TGO in TBCs were investigated using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD) analysis. The growth rate of TGO for TBC and pure BC were gained after isothermal oxidation at 1100 °C for various times. The results showed that as-sprayed bond coat consisted of β and γ/γ'phases,β phase reducesd as the oxidation time increased. The TGO comprised α-Al2O3 formed in the first 2 h. CoO, NiO, Cr2O3 and spinel oxides appeared after 20 h of oxidation. Contents of CoO and NiO reduced while that of Cr2O3 and spinel oxides increased in the later oxidation stage. The TGO eventually consisted of a sub-Al2O3 layer with columnar microstructure and the upper porous CS clusters. The TGO growth kinetics for two kinds of samples followed parabolic laws, with oxidation rate constant of 0.344 μm/h0.5 for TBCs and 0.354 μm/h0.5 for pure BCs.

  14. Wear resistance of Fe-Nb-Cr-W, Nb, AISI 1020 and AISI 420 coatings produced by thermal spray wire arc; Resistencia al desgaste de recubrimientos Fe-Nb-Cr-W, Nb, AISI 1020 y AISI 420 producidos por proyeccion termica por arco electrico

    Energy Technology Data Exchange (ETDEWEB)

    Lopez-Covaleda, E. A.; Mercado-Veladia, J. L.; Olaya-Florez, J. J.

    2013-07-01

    The commercial materials 140MXC (with iron, tungsten, chrome, niobium), 530AS (AISI 1015 steel) and 560AS (AISI 420 steel) on AISI 4340 steel were deposited using thermal spray with arc. The aim of work was to evaluate the best strategy abrasive wear resistance of the system coating-substrate using the following combinations: (1) homogeneous coatings and (2) coatings depositing simultaneously 140MXC + 530AS and 140MXC + 560AS. The coatings microstructure was characterized using Optical microscopy, Scanning electron microscopy and Laser con focal microscopy. The wear resistance was evaluated through dry sand rubber wheel test (DSRW). We found that the wear resistance depends on the quantity of defects and the mechanical properties like hardness. For example, the softer coatings have the biggest wear rates and the failure mode was characterized by plastic deformation caused by particles indentation, and the other hand the failure mode at the harder materials was grooving. The details and wear mechanism of the coatings produced are described in this investigation. (Author)

  15. Highly Corrosion Resistant and Sandwich-like Si3N4/Cr-CrNx/Si3N4 Coatings Used for Solar Selective Absorbing Applications.

    Science.gov (United States)

    Zhang, Ke; Du, Miao; Haoa, Lei; Meng, Jianping; Wang, Jining; Mi, Jing; Liu, Xiaopeng

    2016-12-14

    Highly corrosion resistant, layer-by-layer nanostructured Si3N4/Cr-CrNx/Si3N4 coatings were deposited on aluminum substrate by DC/RF magnetron sputtering. Corrosion resistance experiments were performed in 0.5, 1.0, 3.0, and 5.0 wt % NaCl salt spray at 35 °C for 168 h. Properties of the coatings were comprehensively investigated in terms of optical property, surface morphology, microstructure, elemental valence state, element distribution, and potentiodynamic polarization. UV-vis-near-IR spectrophotometer and FTIR measurements show that the change process in optical properties of Si3N4/Cr-CrNx/Si3N4/Al coatings can be divided into three stages: a rapid active degradation stage, a steady passivation stage, and a transpassivation degradation stage. With the increase in the concentration of NaCl salt spray, solar absorptance and thermal emittance experienced a slight degradation. SEM images reveal that there is an increase in surface defects, such as microcracks and holes and -cracks. XRD and TEM measurements indicate that the phase structure changed partially and the content of CrOx and Al2O3 has increased. Auger electron spectroscopy shows that the elements of Cr, N, and O have undergone a minor diffusion. Electrochemical polarization curves show that the as-deposited Si3N4/Cr-CrNx/Si3N4/Al coatings have excellent corrosion resistance of 3633.858 kΩ, while after corroding in 5.0 wt % NaCl salt spray for 168 h the corrosion resistance dropped to 13.759 kΩ. However, these coatings still have an outstanding performance of high solar absorptance of 0.924 and low thermal emittance of 0.090 after corroding in 3.0 wt % NaCl salt spray for 120 h. Thus, the Si3N4/Cr-CrNx/Si3N4/Al coating is a good choice for solar absorber coatings applied in the high-saline environment.

  16. Sealing of hard CrN and DLC coatings with atomic layer deposition.

    Science.gov (United States)

    Härkönen, Emma; Kolev, Ivan; Díaz, Belén; Swiatowska, Jolanta; Maurice, Vincent; Seyeux, Antoine; Marcus, Philippe; Fenker, Martin; Toth, Lajos; Radnoczi, György; Vehkamäki, Marko; Ritala, Mikko

    2014-02-12

    Atomic layer deposition (ALD) is a thin film deposition technique that is based on alternating and saturating surface reactions of two or more gaseous precursors. The excellent conformality of ALD thin films can be exploited for sealing defects in coatings made by other techniques. Here the corrosion protection properties of hard CrN and diamond-like carbon (DLC) coatings on low alloy steel were improved by ALD sealing with 50 nm thick layers consisting of Al2O3 and Ta2O5 nanolaminates or mixtures. In cross sectional images the ALD layers were found to follow the surface morphology of the CrN coatings uniformly. Furthermore, ALD growth into the pinholes of the CrN coating was verified. In electrochemical measurements the ALD sealing was found to decrease the current density of the CrN coated steel by over 2 orders of magnitude. The neutral salt spray (NSS) durability was also improved: on the best samples the appearance of corrosion spots was delayed from 2 to 168 h. On DLC coatings the adhesion of the ALD sealing layers was weaker, but still clear improvement in NSS durability was achieved indicating sealing of the pinholes.

  17. Sliding Wear Behavior of Plasma Sprayed Zirconia Coating on Cast Aluminum against Silicon Carbide Ceramic

    Institute of Scientific and Technical Information of China (English)

    Thuong-Hien LE; Young-Hun CHAE; Seock-Sam KIM

    2005-01-01

    The sliding wear behaviors of ZrO2-22 wt pct MgO (MZ) and ZrO2-8 wt pct Y2O3 (YZ) coatings deposited on a cast aluminum alloy with bond layer (NiCrCoAlY) by plasma spray were investigated under dry test conditions at room temperature. Under all load conditions, the wear mechanisms of the MZ and YZ coatings were almost the same.The material transfer and pullout were involved in the wear process of the studied coatings under the test conditions.The wear rate of the MZ coating was less than that of the YZ coating. While increasing the normal load, the wear rates of the MZ and YZ coatings increased. SEM was used to examine the worn surfaces and to elucidate likely wear mechanisms. Energy dispersive X-ray spectroscopy (EDX) analysis of the worn surfaces indicated that material transfer occurred in the direction from the SiC ball to the disk. Fracture toughness had a significant influence on the wear performance of the coatings. It was suggested that the material transfer played an important role in the wear behavior.

  18. Evaluation of Ceria-Added Cr3C2-25(NiCr) Coating on Three Superalloys under Simulated Incinerator Environment

    Science.gov (United States)

    Mudgal, Deepa; Singh, Surendra; Prakash, Satya

    2015-02-01

    Cr3C2-25(NiCr) coating is widely used in wear, erosion and corrosion applications. In the present study, D-gun-sprayed Cr3C2-25(NiCr) coatings with and without 0.4 wt.% ceria incorporated were deposited on Superni 718, Superni 600 and Superco 605 substrates. Hot-corrosion runs were conducted in 40 %Na2SO4-40 %K2SO4-10 %NaCl-10 %KCl environment at 900 °C for 100 cycles. Corrosion kinetics was monitored using weight gain measurements. Characterization of corrosion products was carried out by field-emission scanning electron microscopy (FESEM)/energy-dispersive spectroscopy (EDS) and x-ray diffraction (XRD) techniques. It was observed that Cr3C2-25(NiCr) coating with and without added ceria deposited on both of the Ni-based alloys showed resistance to corrosion under the given environment. Addition of ceria enhanced the adherence of the oxide to the coating during the corrosion run and reduced the overall weight gain. However, Cr3C2-25(NiCr)-coated Superco 605 did not perform satisfactorily under this environment.

  19. Manufacturing and Properties of High-Velocity Oxygen Fuel (HVOF)-Sprayed FeVCrC Coatings

    Science.gov (United States)

    Sassatelli, Paolo; Bolelli, Giovanni; Lusvarghi, Luca; Manfredini, Tiziano; Rigon, Rinaldo

    2016-10-01

    This paper studies the microstructure, sliding wear behavior and corrosion resistance of high-velocity oxygen fuel (HVOF)-sprayed FeVCrC-based coatings. Various process parameters were tested to evaluate their effects on the coating properties, which were also compared to those of HVOF-sprayed NiCrBSi and Stellite-6 coatings. The Fe alloy coatings are composed of flattened splats, originating from molten droplets and consisting of a super-saturated solid solution, together with rounded particles, coming from partially unmolten material and containing V- and Fe-based carbide precipitates. All process parameters, apart from "extreme" settings with excess comburent in the flame, produce dense coatings, indicating that the feedstock powder is quite easily processable by HVOF. These coatings, with a microhardness of 650-750 HV0.3, exhibit wear rates of ≈2 × 10-6 mm3/(Nm) in ball-on-disk tests against sintered Al2O3 spheres. They perform far better than the reference coatings, and better than other Fe- and Ni-based alloy coatings tested in previous research. On the other hand, the corrosion resistance of the coating material (tested by electrochemical polarization in 0.1 M HCl solution) is quite low. Even in the absence of interconnected porosity, this results in extensive, selective damage to the Fe-based matrix. This coating material is therefore unadvisable for severely corrosive environments.

  20. Nickel-chromium plasma spray coatings: A way to enhance degradation resistance of boiler tube steels in boiler environment

    Energy Technology Data Exchange (ETDEWEB)

    Sidhu, B.S.; Prakash, S.

    2006-03-15

    Boiler tube steels, namely low carbon steel ASTM-SA210-Grade A1 (GrA1), 1Cr-0.5Mo steel ASTM-SA213-T-11 (T11), and 2.25Cr-1Mo steel ASTM-SA213-T-22 (T22), were used as substrate steels. Ni-22Cr-10AI-1Y powder was sprayed as a bond coat 150 {mu}m thick before a 200 {mu}m final coating of Ni-20Cr was applied. Coatings were characterized prior to testing in the environment of a coal fired boiler. The uncoated and coated steels were inserted in the platen superheater zone of a coal fired boiler at around 755{sup o}C for 10 cycles, each 100 h. Coated steels showed lower degradation (erosion-corrosion) rate than uncoated steels showed. The lowest rate was observed in the case of Ni-20Cr coated T11 steel. Among the uncoated steels, the observed rate of degradation was the lowest for the T22 steel.

  1. Nickel-chromium plasma spray coatings: A way to enhance degradation resistance of boiler tube steels in boiler environment

    Science.gov (United States)

    Sidhu, Buta Singh; Prakash, S.

    2006-03-01

    Boiler tube steels, namely low carbon steel ASTM-SA-210-Grades A1 (GrA1), 1Cr-0.5Mo steel ASTM-SA213-T-11 (T11), and 2.25Cr-1 Mo steel ASTM-SA213-T-22(T22), were used as substrate steels. Ni-22Cr-10Al-1Y powder was sprayed as a bond coat 150 μm thick before a 200 μm final coating of Ni-20Cr was applied Coatings were characterized prior to testing in the environment of a coal fire boiler. The uncoated and coated steels were inserted in the platen superheater zone of a coal fired boiler at around 755°C for 10 cycles, each 100 h. Coated steels showed lower degradation (erosion-corrosion) rate than uncoated steels showed. The lowest rate was observed in the case of Ni-20Cr coated T11 steel. Among the uncoated steels, the observed rate of degradation was the lowest for the T22 steel.

  2. Arc-Sprayed Iron-Based Coatings for Erosion-Corrosion Protection of Boiler Tubes at Elevated Temperatures

    Science.gov (United States)

    Pokhmurskii, Vasyl; Student, Mykhailo; Gvozdeckii, Volodymyr; Stypnutskyy, Taras; Student, Oleksandra; Wielage, Bernhard; Pokhmurska, Hanna

    2013-06-01

    Wire arc spraying is an economically attractive thermal spray process that is especially interesting for the protection of large-scale parts or constructions. This study presents the results of the development and investigation of a number of cored wires based on the Fe-Cr-Al system with minor addition of alloying elements (B, Mn, Ni, Si, Ti, Mg, etc.). The microstructure of the coatings, their electrochemical behavior, and isothermal oxidation performance over a temperature range of 20-700 °C were investigated. Erosion resistance at elevated temperatures was determined with a laboratory test unit under test conditions that have simulated the work conditions in fossil-fuel-fired boilers. It was established that the oxidation resistance and the gas-abrasive wear resistance of arc-sprayed coatings depend mostly on the coating microstructure and homogeneity of element distribution rather than on the general alloying level and microhardness of the coating. A new parameter for coating characterization, namely, the coefficient of chemical microheterogeneity, K CMH, is introduced to quantify this influence. Formation of the coating microstructure at elevated temperatures and its influence on the protection ability of the coating are discussed.

  3. Influence of Heat Treatment on the Bond Coat Cyclic Oxidation Behaviour in an Air-plasma-sprayed Thermal Barrier Coating System

    Institute of Scientific and Technical Information of China (English)

    W.R. Chen; X. Wu; B.R. Marple; P.C. Patnaik

    2004-01-01

    It is generally believed that a thermally grown oxide (TGO) layer of alumina provides enhanced protection to the metallic bond coat in thermal barrier coating (TBC) systems at elevated temperatures. However, in an air-plasma-sprayed (APS) TBC system with Co-32Ni-21Cr-8A1-0.5Y (wt%) bond coat, the TGO layer formed upon thermal exposure in air was predominantly chromia and spinels, which would not effectively protect the bond coat at above 1000℃. In addition,mixed oxides of chromia, spinel and nickel oxide formed heterogeneously between the ceramic coating and CoNiCrAlY bond coat, which would promote crack initiation and lead to premature TBC failure. A heat treatment in a low-pressure condition was applied to the as-sprayed TBC system, with the aim to produce an alumina layer as well as reduce the amount of detrimental oxides. The influence of this low-pressure oxidation treatment (LPOT) on the bond coat cyclic oxidation behaviour of the TBC system was also investigated.

  4. Influence of Heat Treatment on the Bond Coat Cyclic Oxidation Behaviour in an Air-plasma-sprayed Thermal Barrier Coating System

    Institute of Scientific and Technical Information of China (English)

    W.R.Chen; X.Wu; B.R.Marple; P.C.Patnaik

    2004-01-01

    It is generally believed that a thermally grown oxide (TGO) layer of alumina provides enhanced protection to the metallic bond coat in thermal barrier coating (TBC) systems at elevated temperatures. However, in an air-plasma-sprayed (APS) TBC system with Co-32Ni-21Cr-8A1-0.5Y (wt%) bond coat, the TGO layer formed upon thermal exposure in air was predominantly chromia and spinels, which would not effectively protect the bond coat at above 1000℃. In addition, mixed oxides of chromia, spinel and nickel oxide formed heterogeneously between the ceramic coating and CoNiCrA1Y bond coat, which would promote crack initiation and lead to premature TBC failure. A heat treatment in a low-pressure condition was applied to the as-sprayed TBC system, with the aim to produce an alumina layer as well as reduce the amount of detrimental oxides. The influence of this low-pressure oxidation treatment (LPOT) on the bond coat cyclic oxidation behaviour of the TBC system was also investigated.

  5. Cr13Ni5Si2-Based Composite Coating on Copper Deposited Using Pulse Laser Induction Cladding.

    Science.gov (United States)

    Wang, Ke; Wang, Hailin; Zhu, Guangzhi; Zhu, Xiao

    2017-02-10

    A Cr13Ni5Si2-based composite coating was successfully deposited on copper by pulse laser induction hybrid cladding (PLIC), and its high-temperature wear behavior was investigated. Temperature evolutions associated with crack behaviors in PLIC were analyzed and compared with pulse laser cladding (PLC) using the finite element method. The microstructure and present phases were analyzed using scanning electron microscopy and X-ray diffraction. Compared with continuous laser induction cladding, the higher peak power offered by PLIC ensures metallurgical bonding between highly reflective copper substrate and coating. Compared with a wear test at room temperature, at 500 °C the wear volume of the Cr13Ni5Si2-based composite coating increased by 21%, and increased by 225% for a NiCr/Cr3C2 coating deposited by plasma spray. This novel technology has good prospects for application with respect to the extended service life of copper mold plates for slab continuous casting.

  6. SHS Flame Spraying TiC-TiB2 Multiphase Coatings

    Institute of Scientific and Technical Information of China (English)

    WANG Jian-jiang; DU Xin-kang; LU Da-qin; YE Ming-hui; ZHANG Long

    2004-01-01

    Utilizing SHS Reactive Flame Spraying (RFS) technology, TiC-TiB2-Al2O3 multiphase ceramics coatings were produced on steel substrate. Phase constituents and microstructure of the ceramic coatings were analyzed. The procedure of chemical combustion and structure transformation, reactive mechanism, and solidifying behavior during spaying were emphasized. Reactants which influenced on SHS spraying was discussed. SHS reactive spraying processes were studied.Mechanical properties of the coatings were tested.

  7. SHS Flame Spraying TiC-TiB2 Multiphase Coatings

    Institute of Scientific and Technical Information of China (English)

    WANGJian-jiang; DUXin-kang; LUDa-qin; YEMing-hui; ZHANGLong

    2004-01-01

    Utilizing SHS Reactive Flame Spraying (RFS) technology, TiC-TiB2-Al2O3 multiphase ceramics coatings were produced on steel substrate. Phase constituents and microstructure of the ceramic coatings were analyzed. The procedure of chemical combustion and structure transformation, reactive mechanism, and solidifying behavior during spaying were emphasized. Reactants which influenced on SHS spr-aying was discussed. SHS reactive spraying processes were studied, Mechanical properties of the coatings were tested.

  8. Photoelectrode Fabrication of Dye-Sensitized Nanosolar Cells Using Multiple Spray Coating Technique

    Directory of Open Access Journals (Sweden)

    Chien-Chih Chen

    2013-01-01

    Full Text Available This paper presents a spray coating technique for fabricating nanoporous film of photoelectrode in dye-sensitized nanosolar cells (DSSCs. Spray coating can quickly fabricate nanoporous film of the photoelectrode with lower cost, which can further help the DSSCs to be commercialized in the future. This paper analyzed photoelectric conversion efficiency of the DSSCs using spray coated photoelectrode in comparison with the photoelectrode made with the doctor blade method. Spray coating can easily control transmittance of the photoelectrode through the multiple spray coating process. This work mainly used a dispersant with help of ultrasonic oscillation to prepare the required nano-TiO2 solution and then sprayed it on the ITO glasses. In this work, a motor-operated conveyor belt was built to transport the ITO glasses automatically for multiple spray coating and drying alternately. Experiments used transmittance of the photoelectrode as a fabrication parameter to analyze photoelectric conversion efficiency of the DSSCs. The influencing factors of the photoelectrode transmittance during fabrication are the spray flow rate, the spray distance, and the moving speed of the conveyor belt. The results show that DSSC with the photoelectrode transmittance of ca. 68.0 ± 1.5% and coated by the spray coating technique has the best photoelectric conversion efficiency in this work.

  9. Cyclic oxidation behaviour of different treated CoNiCrAlY coatings

    Energy Technology Data Exchange (ETDEWEB)

    Marginean, G. [University of Applied Sciences Gelsenkirchen, Neidenburger Str. 43, 45877 Gelsenkirchen (Germany); Utu, D., E-mail: dutu@eng.upt.ro [University ' Politehnica' Timisoara, Faculty of Mechanical Engineering, Blv. Mihai Viteazu 1, 300222 Timisoara (Romania)

    2012-08-01

    High velocity oxygen fuel (HVOF) spraying method was used in order to obtain very dense and good adhesive CoNiCrAlY-coatings deposited onto nickel-based alloy. The coatings were differently treated (preoxidized, vacuum treated or electron beam irradiated) before their exposure to cyclic oxidation tests in air at 1000 Degree-Sign C for periods up to 5 h. Changes of the coatings morphology and structure were analysed by scanning electron microscopy (SEM) and X-ray diffraction technique (XRD). The surface temperature of the samples was measured during cooling, between the oxidation cycles, and finally was associated with the thickness of the grown protective oxide scale on the CoNiCrAlY-surface. The experimental results demonstrated that depending on the thickness respectively on the different structures of the grown oxide scale, the cooling rate of the sample surface will be different as well.

  10. Electrochemical investigation of chromium oxide-coated Ti-6Al-4V and Co-Cr-Mo alloy substrates.

    Science.gov (United States)

    Swaminathan, Viswanathan; Zeng, Haitong; Lawrynowicz, Daniel; Zhang, Zongtao; Gilbert, Jeremy L

    2011-08-01

    Hard coatings for articulating surfaces of total joint replacements may improve the overall wear resistance. However, any coating approach must take account of changes in corrosion behavior. This preliminary assessment analyzes the corrosion kinetics, impedance and mechanical-electrochemical stability of 100 μm thick plasma sprayed chromium oxide (Cr₂O₃) coatings on bearing surfaces in comparison to the native alloy oxide films on Co-Cr-Mo and Ti-6Al-6V. Cyclic potentiodynamic polarization, electrochemical impedance spectroscopy, and mechanical abrasion under potentiostatic conditions were performed on coated and substrate surfaces in physiological saline. SEM analysis characterized the coating morphology. The results showed that the corrosion current density values of chromium oxide coatings (0.4-1.2 μA/cm²) were of the same order of magnitude as Ti-6Al-4V alloy. Mechanical abrasion did not increase corrosion rates of chromium oxide coatings but did for uncoated Co-Cr-Mo and Ti-6Al-4V. The impedance response of chromium oxide coatings was very different than Co-Cr-Mo and Ti-6Al-4V native oxides characterized by a defected coating model. More of a frequency-independent purely resistive response was seen in mid-frequency range for the coatings (CPE(coat) : 40-280 nF/cm² (rad/s)(1-α) , α: 0.67-0.83) whereas a more capacitive character is seen for Co-Cr-Mo and Ti-6Al-4V (CPE(ox) around 20 μF/cm² (rad/s)(1-α) , α around 0.9). Pores, interparticle gaps and incomplete fusion typical for thermal spray coatings were present in these oxides which could have influenced corrosion resistance. The coating microstructure could have allowed some fluid penetration. Overall, these coatings appear to have suitable corrosion properties for wear surfaces. Copyright © 2011 Wiley Periodicals, Inc.

  11. The relationship between the microstructure and thermal diffusivity of plasma-sprayed tungsten coatings

    Energy Technology Data Exchange (ETDEWEB)

    Moreau, C. [National Research Council Canada, Boucherville, Quebec (Canada); Boire-Lavigne, S.; Saint-Jacques, R.G. [INRS-Energie et Materiaux, Varennes, Quebec (Canada)

    1994-12-31

    Tungsten and tungsten alloy coatings are candidate materials for plasma facing components of divertor plates in future fusion reactors. In normal operation, the sprayed coatings will be submitted to intense heat fluxes and particle bombardment. This work intends to investigate the relationship between the microstructure of plasma-sprayed tungsten coatings and their thermal diffusivity as determined by the laser flash method. The microstructural investigation was carried out on copper-infiltrated coatings. Such a preparation technique permitted the measurement of the total real contact area between the lamellae within the tungsten coatings. The spraying atmosphere was found to strongly influence the interfacial contact between lamellae and coating thermal diffusivity.

  12. Heat load behaviors of plasma sprayed tungsten coatings on copper alloys with different compliant layers

    Energy Technology Data Exchange (ETDEWEB)

    Chong, F.L. [Institute of Plasma Physics, Chinese Academy of Sciences, Hefei 230031 (China)], E-mail: flch@ipp.ac.cn; Chen, J.L.; Li, J.G. [Institute of Plasma Physics, Chinese Academy of Sciences, Hefei 230031 (China); Hu, D.Y.; Zheng, X.B. [Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200051 (China)

    2008-04-15

    Plasma sprayed tungsten (PS-W) coatings with the compliant layers of titanium (Ti), nickel-chromium-aluminum (NiCrAl) alloys and W/Cu mixtures were fabricated on copper alloys, and their properties of the porosity, oxygen content, thermal conductivity and bonding strength were measured. High heat flux tests of actively cooled W coatings were performed by means of an electron beam facility. The results indicated that APS-W coating showed a poorer heat transfer capability and thermo-mechanical properties than VPS-W coating, and the compliant layers improved W coating performance under the heat flux load. Among three compliant layers, W/Cu was the preferable because of its better effects on heat removal and stress alleviating. The optimization of W/Cu compliant layer found that 0.1 mm and 25 vol.%W was optimum compliant layer structure for 1 mm W coating, which induced a 23% reduction of the maximum stress compared to the sharp interface, and the plastic strain was reduced to 0.01% from 1.55%.

  13. Heat load behaviors of plasma sprayed tungsten coatings on copper alloys with different compliant layers

    Science.gov (United States)

    Chong, F. L.; Chen, J. L.; Li, J. G.; Hu, D. Y.; Zheng, X. B.

    2008-04-01

    Plasma sprayed tungsten (PS-W) coatings with the compliant layers of titanium (Ti), nickel-chromium-aluminum (NiCrAl) alloys and W/Cu mixtures were fabricated on copper alloys, and their properties of the porosity, oxygen content, thermal conductivity and bonding strength were measured. High heat flux tests of actively cooled W coatings were performed by means of an electron beam facility. The results indicated that APS-W coating showed a poorer heat transfer capability and thermo-mechanical properties than VPS-W coating, and the compliant layers improved W coating performance under the heat flux load. Among three compliant layers, W/Cu was the preferable because of its better effects on heat removal and stress alleviating. The optimization of W/Cu compliant layer found that 0.1 mm and 25 vol.%W was optimum compliant layer structure for 1 mm W coating, which induced a 23% reduction of the maximum stress compared to the sharp interface, and the plastic strain was reduced to 0.01% from 1.55%.

  14. Optimization and Characterization of High Velocity Oxy-fuel Sprayed Coatings: Techniques, Materials, and Applications

    Directory of Open Access Journals (Sweden)

    Maria Oksa

    2011-09-01

    Full Text Available In this work High Velocity Oxy-fuel (HVOF thermal spray techniques, spraying process optimization, and characterization of coatings are reviewed. Different variants of the technology are described and the main differences in spray conditions in terms of particle kinetics and thermal energy are rationalized. Methods and tools for controlling the spray process are presented as well as their use in optimizing the coating process. It will be shown how the differences from the starting powder to the final coating formation affect the coating microstructure and performance. Typical properties of HVOF sprayed coatings and coating performance is described. Also development of testing methods used for the evaluation of coating properties and current status of standardization is presented. Short discussion of typical applications is done.

  15. Corrosion behavior of Cr/Ni alloy coated ferritic stainless steel in simulated cathodic PEMFC environments

    Energy Technology Data Exchange (ETDEWEB)

    Rendon, M.; Rivas, S.V.; Arriga, L.G.; Orozco, G. [Centro de Investigacion y Desarrollo Tecnologico en Electroquimica, Queretaro (Mexico); Perez-Quiroz, J.T. [Inst. Mexicano del Transporte, Queretaro (Mexico); Porcayo, J. [Inst. de Investigaciones Electricas, Morelos (Mexico)

    2008-07-01

    The bipolar plate in a proton exchange membrane fuel cell (PEMFC) must be corrosion resistant and the interfacial contact resistance (ICR) with the gas diffusion layer must be low. For these reasons, stainless steel with high Cr content is considered to be a viable material for use in bipolar plate construction. This study evaluated the corrosion resistance of ferritic stainless steels 441 and 439, with and without a Cr/Ni coating, under simulated cathodic PEMFC conditions. Steel 441 without coating has a low corrosion current density and can be considered as a candidate material to be used as bipolar plate. The study showed that after the Cr/Ni coating was applied by Thermal Spray Metal method, the corrosion current density increased due to selective dissolution of an alloy element. The corrosion current density of the coatings was higher than the DOE target value, rendering them an unfeasible option to be used in bipolar plates for fuel cell applications. However, previous studies have shown that after the coating was applied, a passivation process improved the corrosion resistance. Although steel 441 appears to be a better candidate than steel 316 because of its lower cost, the behaviour of the Ni-Cr alloys was not satisfactory in corrosive acidic medium. 5 refs.

  16. Investigation of Plasma Spray Coatings as an Alternative to Hard Chrome Plating on Internal Surfaces

    Science.gov (United States)

    2006-09-14

    alloy Ni-988 Praxair WC-Co self fluxing 50%(WC 12Co) 50%(33Ni 9Cr 3.5Fe 2Si 2B 0.5C) SM 5803 Sulzer Metco (WC 12Co) 25(Ni-Based Superalloy ) SM...Micro Hardness [HV0.3] Cracks 10012402-1 SM 5803 (WC 12Co) 25(Ni-Based Superalloy ) Ar/He/H2 5.3 82.2 671 Micro cracks 10012502-1 D2002 (WC...o n V o lu m e L o ss ( m m 3 ) Figure 4-28. Abrasion resistance of EHC and plasma spray coatings. Ring Coated (block) disc Figure

  17. [Preparation of electrodeposited Cr-La coating and its spectral properties].

    Science.gov (United States)

    Liu, Xiao-zhen; Wang, Gang; Song, Ling-ling; Li, Xin; Zhu, Xu-qiang

    2011-07-01

    Cr-La coating (dc) and Cr-La coating (pulse) were prepared by electrodeposition method of direct current and pulsating current respectively. The Cr-La coating (dc) and Cr-La coating (pulse) were characterized with ICP-AES, EDAX, XRD and SEM techniques, respectively. Cr-La coating(dc) was amorphous. There were crystalline La and CrC in Cr-La coating (pulse). The microhardness of the Cr-La coating(dc) and Cr-La coating (pulse) were as high as 860.3 and 930.2 HV respectively, which were higher 11.15% and 20.18% higher than that of the Cr coating (774.0 HV). The wear weight losses of Cr-La coating(dc) and Cr-La coating(pulse) were 1.29 and 2.25 times lower than that of Cr coating, respectively. The friction coefficient of Cr coating, Cr-La coating(dc) and Cr-La coating(pulse) were 0. 884, 0. 640 and 0. 648 respectively. The properties of wear weight loss and microhardness of coatings were improved with pulsating current. The wear weight loss and microhardness of Cr-La coating(pulse) were lower 1.75 time lower and higher 8.13% higher than that of the Cr-La coating(dc), respectively.

  18. Lubricated wear of NiCrBSi coatings partially remelted with laser; Desgaste lubricado de recubrimientos NiCrBSi refundidos parcialmente con laser

    Energy Technology Data Exchange (ETDEWEB)

    Vijande, R.; Cuetos, J. M.; Cortizo, J. L.; Rodriguez, E.; Noriega, A.

    2009-07-01

    Plasma sprayed nickel based coatings are widely used at the industry due to their good wear behaviour. The laser remelting of these coatings eliminates or strongly decreases their porosity and increases their microhardness and adherence with the substrate. In this work, we define the laser meshing as the partial re fusion of the coatings surface. This technique is applied to a NiCrBSi coating in order to achieve better anti-wear outcomes, combining the advantages of plasma spraying and laser remelting. The results are experimentally verificated and they quantify themselves attending to the variables percentage of remelted surface and angle of meshing cord (remelting trace of successive parallel tracks by a laser beam). The experimental process is developed following the DOE methodology, to optimize both the test process and the objective function of minimum wear in lubricated contact. (Author) 18 refs.

  19. Hot Corrosion Behavior of Bare, Cr3C2-(NiCr) and Cr3C2-(NiCr) + 0.2wt.%Zr Coated SuperNi 718 at 900 °C

    Science.gov (United States)

    Mudgal, Deepa; Singh, Surendra; Prakash, Satya

    2015-01-01

    Corrosion in incinerators, power plants, and chemical industries are frequently encountered due to the presence of salts containing sodium, sulphur, and chlorine. To obviate this problem, bare and coated alloys were tested under environments simulating the conditions present inside incinerators and power plants. 0.2 wt.% zirconium powder was incorporated in the Cr3C2-(NiCr) coating powder. The original powder and Zr containing powder was sprayed on Superni 718 alloy by D-gun technique. The bare and coated alloys were tested under Na2SO4 + K2SO4 + NaCl + KCl and Na2SO4 + NaCl environment. The corrosion rate of specimens was monitored using weight change measurements. Characterization of the corrosion products has been done using FE-SEM/EDS and XRD techniques. Bare and coated alloys showed very good corrosion resistance under given molten salt environments. Addition of 0.2wt.%Zr in Cr3C2-25%(NiCr) coating further greatly reduced the oxidation rate as well as improved the adherence of oxide scale to the coating surface during the time of corrosion.

  20. Oxidation Behavior of Thermal Sprayed NiCrAl Coating and Thermal Barrier Coating on Titanium Alloy Surface%钛合金表面热喷涂NiCrAl涂层和热障涂层的氧化性能

    Institute of Scientific and Technical Information of China (English)

    谢旭霞; 张乐; 张鑫; 李新虎; 彭露; 任先京

    2009-01-01

    采用超音速等离子喷涂技术在TC4和Ti40钛合金表面制备NiCrAl及NiCrAl+ ZrO2热障涂层,测定TC4、TC4+ NiCrAl 、TC4+ NiCrAl + ZrO2、Ti40、Ti40+NiCrAl、Ti40+NiCrAl+ ZrO2在600 ℃下的氧化动力曲线.通过扫描电镜(SEM)和能谱(EDS)分析研究钛合金、NiCrAl涂层和热障涂层组织形貌.结果表明:TC4在600 ℃的抗氧化性能优于Ti40;NiCrAl涂层与热障涂层能明显提高TC4和Ti40在600 ℃下的抗氧化性;600 ℃下氧化100 h后,NiCrAl涂层、NiCrAl+ZrO2 涂层与TC4界面处出现了扩散带和锯齿状的相,而与Ti40界面处只出现了扩散带,未发现锯齿状的相.

  1. Development of plasma spray coating using coal ash

    Energy Technology Data Exchange (ETDEWEB)

    Mishra, S.C.; Sarkar, P.C.; Mishra, P.C.; Sreekumar, K.P.; Padmanabhan, P.V.A. [Regional Engineering College, Rourkela (India)

    2000-07-01

    In India about 70 million tonnes of fly ash is generated annually and the figure is growing at a faster rate due to industrial and urban demand. Worldwide, fly ash is being used to generate value added products. In India about 10% of fly ash generated is utilised and if feverish activity is not initiated the percent utilisation can go down. The present piece of work has been undertaken to use the fly ash and graphite (from the rejected electrodes of arc furnaces) for developing plasma spray composite coating on metal substrates. Fly ash and graphite powder (at 10% and 20% wt) mix was plasma sprayed at various operating conditions of the plasma torch on different metal substrate, viz. copper and stainless steel. The coating thus formed was characterised by X-ray diffraction analysis, electron microscopy, microhardness measurement and measurement of interface adhesion strength. A maximum coating thickness of {approximately} 220 micron is obtained with fly ash +20% graphite. The adherence strength is found to vary between 10-35 MNm{sup 2} and is maximum in case of copper substrates. 8 refs., 4 figs., 1 tab.

  2. Thermal stability of Al-Cr-N hard coatings

    Energy Technology Data Exchange (ETDEWEB)

    Willmann, H. [Materials Center Leoben, Franz-Josef Strasse 13, 8700 Leoben (Austria) and IFM Material Physics, Division of Thin Film Physics, Linkoeping University, 58183 Linkoeping (Sweden)]. E-mail: herbert.willmann@unileoben.ac.at; Mayrhofer, P.H. [Department of Physical Metallurgy and Materials Testing, University of Leoben, 8700 Leoben (Austria); Materials Chemistry, RWTH-Aachen, 52074 Aachen (Germany); Persson, P.O.A. [IFM Material Physics, Division of Thin Film Physics, Linkoeping University, 58183 Linkoeping (Sweden); FEI Company, 5651 GG Eindhoven (Netherlands); Reiter, A.E. [Balzers Ltd., 9496 Balzers (Liechtenstein); Hultman, L. [IFM Material Physics, Division of Thin Film Physics, Linkoeping University, 58183 Linkoeping (Sweden); Materials Chemistry, RWTH-Aachen, 52074 Aachen (Germany); Mitterer, C. [Department of Physical Metallurgy and Materials Testing, University of Leoben, 8700 Leoben (Austria); Christian Doppler Laboratory for Advanced Hard Coatings, University of Leoben, 8700 Leoben (Austria)

    2006-06-15

    Heat treatment of arc-evaporated cubic Al{sub 0.7}Cr{sub 0.3}N hard coatings in Ar up to 1450 deg. C causes precipitation of AlN. The Cr-enriched matrix transforms into Cr via Cr{sub 2}N under N{sub 2} release. These reactions are investigated by simultaneous thermal analysis, mass spectrometry, X-ray diffraction, and analytical transmission electron microscopy.

  3. Highly durable superhydrophobic coatings with gradient density by movable spray method

    Science.gov (United States)

    Tenjimbayashi, Mizuki; Shiratori, Seimei

    2014-09-01

    Superhydrophobic surface is expected to be applied in anti-fouling, anti-icing, and anti-bacterial. However, practical use is interrupted by low mechanical strength, time-consuming process, and limited coating substrate. Here highly durable superhydrophobic coatings were prepared by simple and novel spraying method, which sprays with changing the "spray distance between substrate and spray" (SD), named "movable spray method." We prepared the solution that changes wettability and durability with spraying distance by mixing SiO2 nanoparticles and ethyl alpha cyanoacrylate polymer (EAC). Then, we evaluated the chemical components and surface morphologies of each spraying distance coatings (0 ˜ 50 cm) by XPS, SEM, and laser scanning microscope. It revealed that surface roughness and SiO2/EAC ratio increased as the SD increases. Thus, durable superhydrophobic coatings were designed by spraying with increasing SD gradually. Glow discharge-optical emission spectrometry analysis revealed that designed coatings showed the gradual increase of SiO2/EAC ratio. As a result, coatings prepared on glass, wood, or aluminum substrates maintained their superhydrophobicity up to the abrasion at 40 kPa. This movable spray method is simple coating by the wet process and prepares robust hydrophobic coating on complex shape and large area substrates. The gradient functional surface was found to have mechanical durability and superhydrophobicity, and wide area applications will be expected.

  4. Comparison of W–TiC composite coatings fabricated by atmospheric plasma spraying and supersonic atmospheric plasma spraying

    Energy Technology Data Exchange (ETDEWEB)

    Hou, Qing Yu, E-mail: qingyuhou@hotmail.com [School of Material Science and Engineering, Hefei University of Technology, Hefei, Anhui 230009 (China); Anhui Key Laboratory of Metal Materials and Processing, Maanshan, Anhui 243002 (China); Luo, Lai Ma [School of Material Science and Engineering, Hefei University of Technology, Hefei, Anhui 230009 (China); Huang, Zhen Yi; Wang, Ping; Ding, Ting Ting [Anhui Key Laboratory of Metal Materials and Processing, Maanshan, Anhui 243002 (China); Wu, Yu Cheng, E-mail: ycwu@hfut.edu.cn [School of Material Science and Engineering, Hefei University of Technology, Hefei, Anhui 230009 (China)

    2016-04-15

    Highlights: • W–TiC composite coatings were fabricated by APS and SAPS technologies. • TiC had filling effect on pores and coating/fixing effect on un-melted particles. • Porosity and oxygen content in SAPS coating were lower than that in APS coating. • Thermal conductivity of SAPS coating was higher than that of APS coating. • SAPS coating has better ability to resist to elastic fracture than APS coating does. - Abstract: Tungsten coatings with 1.5 wt.% TiC (W/TiC) were fabricated by atmospheric plasma spraying (APS) and supersonic atmospheric plasma spraying (SAPS) techniques, respectively. The results showed that the typical lamellar structure of plasma spraying and columnar crystalline grains formed in the coatings. Pores located mainly at lamellar gaps in association with oxidation were also observed. TiC phase, distributed at lamellar gaps filled the gaps; and that distributed around un-melted tungsten particles and splashed debris coated the particles or debris that were linked with the TiC at lamellar gaps. The coating and linking of the retained TiC phase prevented the tungsten particles to come off from the coatings. The porosity and the oxygen content of the SAPS-W/TiC were lower than those of the APS-W/TiC coating. The mechanical response of the coatings was strongly dependent on the H/E* ratio (H and E* are the hardness and effective Young’s modulus, respectively). The SAPS-W/TiC coating with a higher H/E* ratio had a better ability to resist to elastic fracture and better fracture toughness as compared with the APS-W/TiC coating with a smaller H/E* ratio. The thermal conductivity of the SAPS-W/TiC coating was greater than that of the APS-W/TiC coating.

  5. Influence of Fracture Toughness and Microhardness on the Erosive Wear of Cermet Coatings Deposited by Thermal Spray

    Science.gov (United States)

    Mojena, Miguel Reyes; Orozco, Mario Sánchez; Fals, Hipólito Carvajal; Ferraresi, Valtair Antonio; Lima, Carlos Roberto Camello

    2017-02-01

    An evaluation of the relationship between the microhardness and fracture toughness with resistance to erosive wear of WC10Co4Cr, WC-12Co, and Cr3C2-25NiCr coatings was conducted. Powder and flexible cored wire feedstock materials were applied by high-velocity oxygen fuel (HVOF) and flame spray (FS), respectively. The erosive wear mechanism prevailing in the coatings was found to be brittle, which also explains the higher erosion rate for the experimental condition using the particle impact angle of 90 deg and impact velocity of 9.33 m/s. The best wear performance was for the coatings applied by HVOF that attains 1.83 mm3/kg for the 90 deg/3.61 m/s test condition. The coating obtained with the WC-10Co4Cr material using the FSFC method showed tungsten carbide decarburization, justifying its poor mechanical properties and poor performance in the erosive wear test. Flame-sprayed flexicords proved to be a promising alternative to HVOF in obtaining coatings with low porosity and acceptable mechanical properties, especially in applications where the use of the HVOF technique is inadequate because of inaccessibility or excessively high cost. Values of K c for the coatings obtained by HVOF (7.35 to 10.83 MPa.m1/2) were between two and three times greater than the values obtained for the coatings resulting from FSFC (2.39 to 3.59 MPa.m1/2), in a similar manner as with the microhardness.

  6. Cr-Ni ALLOY ELECTRODEPOSITION AND COMPARISON WITH CONVENTIONAL PURE Cr COATING TECHNIQUE

    OpenAIRE

    Moniruzzaman, M; M.M. Rakib; F.T. Matin

    2012-01-01

    Cr coating is widely used as the outer surface of precision parts due to its attractive appearance and superior corrosion resistance properties. It is obtained by electrodeposition via a conventional bath with hexavalent Cr ions. This manufacturing technique has many drawbacks, such as very low efficiency and high operating temperature and it is hazardous to health. In this work, we studied a Cr-Ni alloy deposition technique and compared the alloy coating properties to those with conventional...

  7. Effect of Composition of Bond Coating on the Durability of the Plasma Sprayed Zr O[sub 2]-Ce O[sub 2]-Y[sub 2] O[sub 3] Thermal Barrier Coating

    Energy Technology Data Exchange (ETDEWEB)

    Kim, H.S. (Korea Institute of Science and Technology, Seoul (Korea, Republic of)); Kim, B.H.; Suhr, D.S. (Chungnam National University, Taejon (Korea, Republic of))

    1999-01-01

    The effect of alloy compositions of the bond coating on the plasma sprayed-thermal barrier coatings was investigated. The performance of the coating composed of Rene 80/NiCrAl/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] and Rene 80/CoNiCrAlY/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] was evaluated by isothermal and thermal cyclic test in an ambient atmosphere at 1150 deg. C. The failure of Rene 80/NiCrAl/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] coatings was occurred at the bond coating/ceramic coating interface while Rene 80/CoNiCrAlY/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] coating was failed at the substrate/bond coating interface after thermal cyclic test. The lifetime of Rene 80/NiCrAl/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] coatings was longer than Rene 80/CoNiCrAlY/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] coating. The oxidation rate of the NiCrAl bond coating examined by TGA was lower than CoNiCrAlY bond coating. In summary, these results suggest that Rene 80/CoNiCrAlY/ZrO[sub 2]-CeO[sub 2]-Y[sub 2]O[sub 3] system as thermal barrier coating be not suitable considering the durability of the coating layer for high temperature oxidation and thermal stress. (author). 12 refs., 14 figs., 2 tabs.

  8. Effect of Composition of Bond Coating on the Durability of the Plasma Sprayed Zr O{sub 2}-Ce O{sub 2}-Y{sub 2} O{sub 3} Thermal Barrier Coating

    Energy Technology Data Exchange (ETDEWEB)

    Kim, H.S. [Korea Institute of Science and Technology, Seoul (Korea, Republic of); Kim, B.H.; Suhr, D.S. [Chungnam National University, Taejon (Korea, Republic of)

    1999-01-01

    The effect of alloy compositions of the bond coating on the plasma sprayed-thermal barrier coatings was investigated. The performance of the coating composed of Rene 80/NiCrAl/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} and Rene 80/CoNiCrAlY/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} was evaluated by isothermal and thermal cyclic test in an ambient atmosphere at 1150 deg. C. The failure of Rene 80/NiCrAl/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} coatings was occurred at the bond coating/ceramic coating interface while Rene 80/CoNiCrAlY/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} coating was failed at the substrate/bond coating interface after thermal cyclic test. The lifetime of Rene 80/NiCrAl/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} coatings was longer than Rene 80/CoNiCrAlY/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} coating. The oxidation rate of the NiCrAl bond coating examined by TGA was lower than CoNiCrAlY bond coating. In summary, these results suggest that Rene 80/CoNiCrAlY/ZrO{sub 2}-CeO{sub 2}-Y{sub 2}O{sub 3} system as thermal barrier coating be not suitable considering the durability of the coating layer for high temperature oxidation and thermal stress. (author). 12 refs., 14 figs., 2 tabs.

  9. Quantitative Topographical Characterization of Thermally Sprayed Coatings by Optical Microscopy

    Science.gov (United States)

    Schwaller, P.; Züst, R.; Michler, J.

    2009-03-01

    Topography measurements and roughness calculations for different rough surfaces (Rugotest surface comparator and thermally sprayed coatings) are presented. The surfaces are measured with a novel quantitative topography measurement technique based on optical stereomicroscopy and a comparison is made with established scanning stylus and optical profilometers. The results show that for most cases the different methods yield similar results. Stereomicroscopy is therefore a valuable method for topographical investigations in both quality control and research. On the other hand, the method based on optical microscopy demands a careful optimization of the experimental settings like the magnification and the illumination to achieve satisfactory results.

  10. Cr(VI) and Cr(III)-Based Conversion Coatings on Zinc

    NARCIS (Netherlands)

    Zhang, X.

    2005-01-01

    With the aims of understanding the protective mechanism of chromate conversion coatings and developing alternatives to chromate treatments, the physical natures and corrosion properties of Cr(VI) and Cr(III) treated zinc have been investigated in this work. The Cr(VI) treatments were carried out in

  11. Cr(VI) and Cr(III)-Based Conversion Coatings on Zinc

    NARCIS (Netherlands)

    Zhang, X.

    2005-01-01

    With the aims of understanding the protective mechanism of chromate conversion coatings and developing alternatives to chromate treatments, the physical natures and corrosion properties of Cr(VI) and Cr(III) treated zinc have been investigated in this work. The Cr(VI) treatments were carried out in

  12. A statistical approach to optimize the spray drying of starch particles: application to dry powder coating.

    Science.gov (United States)

    Bilancetti, Luca; Poncelet, Denis; Loisel, Catherine; Mazzitelli, Stefania; Nastruzzi, Claudio

    2010-09-01

    This article describes the preparation of starch particles, by spray drying, for possible application to a dry powder coating process. Dry powder coating consists of spraying a fine powder and a plasticizer on particles. The efficiency of the coating is linked to the powder morphological and dimensional characteristics. Different experimental parameters of the spray-drying process were analyzed, including type of solvent, starch concentration, rate of polymer feeding, pressure of the atomizing air, drying air flow, and temperature of drying air. An optimization and screening of the experimental parameters by a design of the experiment (DOE) approach have been done. Finally, the produced spray-dried starch particles were conveniently tested in a dry coating process, in comparison to the commercial initial starch. The obtained results, in terms of coating efficiency, demonstrated that the spray-dried particles led to a sharp increase of coating efficiency value.

  13. Effect of grit blasting pre-treatment on bond strength of TiAl-Nb/NiCrAl coatings sprayed by high velocity oxyfuel%喷砂预处理对HVOF喷涂TiAl-Nb/NiCrAl涂层结合强度的影响

    Institute of Scientific and Technical Information of China (English)

    张来启; 张少杰; 曾红杰; 林均品; 陈国良

    2011-01-01

    采用不同的喷砂压力对基体表面进行喷砂预处理,研究了基体表面状态的变化对HVOF喷涂TiAl-Nb/NiCrAl涂层结合强度的影响。结果表明:随着喷砂压力的增大,基体粗糙度及表面凹坑的深度和宽度增大,NiCrAl层与基体结合界面处孔洞等缺陷增多,同时基体表面残余砂粒的面积分数增加;涂层结合强度随基体粗糙度的增大,先增大后减小,当基体粗糙度为8.33μm时,结合强度达到最大值44.5 MPa。%Grit blasting pre-treatment on substrate surface of SUS316L stainless steel was carried out by changing the grit blasting pressure.Variation of the substrate surface state and its influence on bond strength of high velocity oxy-fuel sprayed(HVOF) TiAl-Nb/NiCrAl coatings were studied.The results show that substrate surface roughness,width and depth of pits on substrate surface,pores at the interface between substrate and NiCrAl coating,and area fraction of residual grits on the surface all increase with increasing of grit blasting pressure.The bond strength of coatings firstly increases and then decreases with increasing of substrate surface roughness,it can reach the maximum value of 44.5 MPa when the substrate surface roughness Ra is 8.33 μm.

  14. Mechanical Behavior of Spray-Coated Metallic Laminates

    Science.gov (United States)

    Vackel, Andrew; Nakamura, Toshio; Sampath, Sanjay

    2016-06-01

    Thermal spray (TS) coatings have been extensively utilized for various surface modifications such as enhancing wear/erosion resistance and thermal protection. In the present study, a new function of TS material is explored by studying its load-carrying capability. Due to the inherent microstructures containing voids and interfaces, it has been presumed TS materials were not suitable to bear loads. However, the recent advances in TS technology to manufacture near fully dense TS coatings have expanded their potential applications. In the current experiments, TS nickel coatings are deposited onto metallic substrates, and their mechanical behaviors are closely examined. Based on the measured data, the estimated elastic modulus of TS Ni is about 130 GPa (35% less than bulk value), and the maximum tensile strength is about 500 MPa (comparable to bulk value). It was found that such a high value is attainable because the coating is deposited onto a substrate, enabling a load-transfer mechanism and preventing coating failure at a much lower stress level. Three distinct deformation stages are identified to describe this behavior. Such a clarification is critical for enabling TS process to restore structural parts as well as to additively manufacture load-bearing components.

  15. New ceramic coating technique using laser spraying process

    Science.gov (United States)

    Tsukamoto, Koichi; Yanagisawa, Takeshi; Uchiyama, Futodhi; Obara, Akira; Okutomi, Mamoru; Kimura, Shinji; Yamada, Akimasa; Shen, Hong L.; Wang, Zhongcheng; Shen, Qinwo; Chatterjee, Udit; Bhar, Gopal C.

    1998-08-01

    A new ceramic coating technique using a CO2 laser has been developed. A high power density laser beam passes near the substrate. Coating materials are supplied by an extra-high accuracy powder supply device and pass across the laser beam. The coating materials are melted in the laser beam and deposited on the substrate surface. A YSZ (Yttria Stabilized Zirconia) layer and a LaCoO3 layer are made for high temperature solid oxide fuel cells. The crystal structures of the coated layers are the same as that of the original coating materials. Superconducting BPSCCO ceramic films are also made with this process. The films show super-conductivity with Tc at 81 K. The Jc of the specimen is 440 A/cm2 at 77 K. We can easily handle and arrange not only metal but also refractory materials. By adopting a multi-axis robot and a surface treatment laser technique, the laser spraying method described here makes it possible to produce highly functional and three dimensional parts of devices directly from raw powder materials. Thus the proposed method will open the path to an unexplored field of key production technology.

  16. Iron-Based Amorphous Coatings Produced by HVOF Thermal Spray Processing-Coating Structure and Properties

    Energy Technology Data Exchange (ETDEWEB)

    Beardsley, M B

    2008-03-26

    The feasibility to coat large SNF/HLW containers with a structurally amorphous material (SAM) was demonstrated on sub-scale models fabricated from Type 316L stainless steel. The sub-scale model were coated with SAM 1651 material using kerosene high velocity oxygen fuel (HVOF) torch to thicknesses ranging from 1 mm to 2 mm. The process parameters such as standoff distance, oxygen flow, and kerosene flow, were optimized in order to improve the corrosion properties of the coatings. Testing in an electrochemical cell and long-term exposure to a salt spray environment were used to guide the selection of process parameters.

  17. Relation between surface roughness of free films and process parameters in spray coating.

    Science.gov (United States)

    Perfetti, G; Alphazan, T; van Hee, P; Wildeboer, W J; Meesters, G M H

    2011-02-14

    A novel spraying apparatus was developed to obtain reproducible free sprayed films. Aqueous solutions of PolyVinyl Alcohol PVA 4-98, HydroxyPropyl MethylCellulose HPMC 603 and HPMC 615 were used as reference coating materials. The apparatus is composed by a spraying system, a closed chamber containing a rotating Teflon cylinder, a pressured air supply system, a spray solution supply system, and a computerized control system. The spraying air pressure, the cylinder rotation speed, and the cylinder-spray nozzle distance were tailored in such a manner that the roughness of the obtained free films was similar to that from reference coated particles. Optimum spraying process conditions were found for all three coating materials using design of experiments. The morphology of the sprayed films obtained using the optimum conditions is evaluated by means of scanning electron microscopy (SEM), and atomic force microscopy (AFM), and then compared with those from corresponding cast films and coating layers on particles. A match was found between the morphology of sprayed films and that from the corresponding coating layer on the particle surface. The spray apparatus produced reproducible sprayed films with tuneable roughness and/or smoothness depending on the set of processing parameters. Copyright © 2010 Elsevier B.V. All rights reserved.

  18. Investigation of the Wear and Hardness Behaviour of Aluminium Alloy Coated Using the Powder Flame Spraying Method

    Directory of Open Access Journals (Sweden)

    Nurullah KIRATLI

    2009-03-01

    Full Text Available In this study, the wear behavior of aluminum alloy AL 5754 ( Etial 53 coated with powders of 10Al-Cu alloy (RotoTec® 19850 and 15Cr7Fe-Ni alloy (RotoTec® 19985 using powder flame spraying method has been investigated. To avoid thermal expansions between substrate and coating materials, Ni-Al RotoTec® 51000 was used as binding material. The wear test was performed on a pin-on-disc test apparatus. As an abrasive material, a SiC, 800 sandpaper was used. The wear tests of coated materials were carried out at room temperature and at 1.0m/s sliding speed with 0.35 and 0.70MPa pressures. To characterize coated specimens, they have been examined with optical microscope. As a result, it is found that the both coating materials have improved wear resistance.

  19. Acoustic Emission Investigation of Rolling/Sliding Contact Fatigue Failure of NiCr-Cr3C2 Coating

    Science.gov (United States)

    Guolu, Li; Zhonglin, Xu; Tianshun, Dong; Haidou, Wang; Jinhai, Liu; Jiajie, Kang

    2016-08-01

    NiCr-Cr3C2 coating was fabricated using supersonic plasma spraying technology. Subsequently, rolling/sliding contact fatigue (R/SCF) testing was carried out, using acoustic emission (AE) technology to monitor the failure process. The results showed that R/SCF consists of three failure modes, namely abrasion, spalling, and delamination. Abrasion is the main failure mode, but delamination is the most severe. The AE monitoring results indicated that the R/SCF failure process is composed of normal contact, crack initiation, crack propagation, and material removal stages. The frequency of each stage was analyzed by fast Fourier transform, revealing a peak frequency for each stage mainly distributed from 200 to 250 kHz.

  20. Coating Layer and Corrosion Protection Characteristics in Sea Water with Various Thermal Spray Coating Materials for STS304

    Science.gov (United States)

    Kim, Seong-Jong; Woo, Yong-Bin

    We investigated the optimal method of application and the anticorrosive abilities of Zn, Al, and Zn + 15%Al spray coatings in protecting stainless steel 304 (STS304) in sea water. If a defect such as porosity or an oxide layer, causes STS304 to be exposed to sea water, and the thermal spray coating material will act as the cathode and anode, respectively. The Tafel experiments revealed that Al-coated specimens among applied coating methods had the lowest corrosion current densities. As the corrosion potential decreases with increasing corrosion current density, we estimated the characteristics and lifetime of the protective thermal spray coating layer in the galvanic cell formed by the thermal spray coating layer and STS304.

  1. Mechanical properties of V-4Cr-4Ti alloy after first-wall coating with tungsten

    Energy Technology Data Exchange (ETDEWEB)

    Nagasaka, Takuya, E-mail: nagasaka@nifs.ac.jp [National Institute for Fusion Science, Oroshi Toki 509-5292 (Japan); Muroga, Takeo [National Institute for Fusion Science, Oroshi Toki 509-5292 (Japan); Watanabe, Hideo [Research Institute for Applied Mechanics, Kyushu University, Kasuga, Fukuoka 816-8580 (Japan); Kasada, Ryuta; Iwata, Noriyuki; Kimura, Akihiko [Institute of Advanced Energy, Kyoto University, Kyoto 611-0011 (Japan)

    2011-10-01

    A first-wall coating was fabricated with tungsten on a reference V-4Cr-4Ti alloy (NIFS-HEAT-2, NH2) substrate by a vacuum plasma spray (VPS) process and brazing (BR). The hardness, fracture stress, and elastic modulus of tungsten (W) coating applied by the vacuum plasma spray process (VPS-W) were lower than the tungsten used for brazing (BR-W). The low mass density and defects of VPS-W are thought to be responsible for the degradation of the strength. The NH2 substrate indicated hardening and embrittlement produced by the W coating and some post-coating heat treatment (PCHT). Hardening and embrittlement by a VPS coating can be recovered by removing hydrogen from the NH2 substrate in a vacuum by annealing at 673 K. Oxygen transfer from the W coating to the NH2 substrate was indicated above 1173 K but did not induce embrittlement of the substrate. Hardening by the BR process can be recovered by PCHT at 1273 K, but embrittlement was not improved. The mechanisms of the hardening and embrittlement are discussed based on a microstructural analysis.

  2. Fracture behavior of 304 stainless steel coatings by cold gas dynamic spray

    Institute of Scientific and Technical Information of China (English)

    Wei HAN; Xianming MENG; Jie ZHAO; Junbao ZHANG

    2011-01-01

    304 stainless steel coating was deposited on the Interstitial-Free steel substrate by cold gas dynamic spraying (CGDS). Three-point bending test of the cold sprayed 304 stainless steel coating was tested by SHIMADZU electro-hydraulic servo-controlled fatigue testing machine and the fracture morphology was examined by scanning electron microscopy. The results showed that the fracture behavior of the cold sprayed 304 stainless steel coating was brittleness fracture. The crack in the coating occurred in the interfaces between particles and the crack extended to the internal of the coating with the increase of the load. When the crack has extended to the combination interface between coating and substrate, the crack extended to the two sides. The microstructure and mechanical property of the cold sprayed 304 stainless steel coating have been optimized after heat treatment.

  3. Influence of coating defects on the corrosion behavior of cold sprayed refractory metals

    Science.gov (United States)

    Kumar, S.; Rao, A. Arjuna

    2017-02-01

    The defects in the cold sprayed coatings are critical in the case of corrosion performances of the coatings in aggressive conditions. To understand the influence of coating defects on corrosion, immersion tests have been carried out in HF solution for the cold sprayed and heat treated Titanium, Tantalum and Niobium coatings. Long duration immersion tests reveal inhomogeneous weight losses of the samples prepared at different heat treatment conditions. The weight loss for different coatings has been well corroborated with the coating defects and microstructures. Chemical and micro structural analysis elucidates the reason behind the inhomogeneous performance of different type of cold sprayed coatings in corrosion medium. In the case of cold sprayed titanium, formation of stable oxide along the inter-splat boundary hinders the aggressive attack of the corrosion medium which is not so in other cases.

  4. Residual stresses determination in textured substrates for plasma sprayed coatings

    Science.gov (United States)

    Capek, J.; Pala, Z.; Kovarik, O.

    2015-04-01

    In this contribution, we have striven to respond to the desire of obtaining the residual stress tensor in the both cold-rolled and hot-rolled substrates designated for deposition of thermal coatings by plasma spraying. Residual stresses play an important role in the coating adhesion to the substrate and, as such, it is a good practice to analyse them. Prior to spraying, the substrate is often being grit blasted. Residual stresses and texture were quantitatively assessed in both virgin and grit blasted sample employing three attitudes. Firstly without taking preferred orientation into account, secondly from measurements of interplanar lattice spacings of planes with high Miller indices using MoKα radiation. And eventually, by calculating anisotropic elastic constants as a weighted average between single-crystal and X-ray elastic constants with weighting being done according to the amount of textured and isotropic material in the irradiated volume. In the ensuing verification analyses, it was established that the latter approach is suitable for materials with either very strong or very weak presence of texture.

  5. Relationships between spray parameters, microstructures and ultrasonic cavitation erosion behavior of HVOF sprayed Fe-based amorphous/nanocrystalline coatings.

    Science.gov (United States)

    Qiao, Lei; Wu, Yuping; Hong, Sheng; Zhang, Jianfeng; Shi, Wei; Zheng, Yugui

    2017-11-01

    Fe-based amorphous/nanocrystalline coatings were prepared on the AISI 321 steel substrate by the high-velocity oxygen-fuel (HVOF) thermal spraying technology. The effect of selected parameters (oxygen flow, kerosene flow and spray distance) on the cavitation erosion resistance (denoted as Rc) of the coating were investigated by using the Taguchi method. Statistical tools such as design of experiments (DOE), signal-to-noise (S/N) ratio and analysis of variance (ANOVA) were used to meet the expected objective. It was concluded that the kerosene flow had greater influence on the Rc of the coating and followed by the spray distance and the oxygen flow, respectively. The optimum spray parameters (OSP) were 963L/min for the oxygen flow, 28L/h for the kerosene flow, and 330mm for the spray distance. The Rc of the coating increased with the increase of hardness or the decrease of porosity, and the hardness had a greater influence on Rc than the porosity. The Fe-based coating deposited under the OSP exhibited the best cavitation erosion resistance in distilled water. The cracks initiated at the edge of the pores and the interfaces between the un-melted or half-melted particles, and finally leaded to the delamination of the coating. Copyright © 2017 Elsevier B.V. All rights reserved.

  6. Sliding Wear Behavior of Plasma Sprayed Alumina-Based Composite Coatings against Al2O3 Ball

    Institute of Scientific and Technical Information of China (English)

    Minh-quy Le; Young-hun Chae; Seock-sam Kim

    2004-01-01

    The sliding wear behaviors of a single layer Al2O3-30 wt pct ZrO2, a double layer Al2O3-30 wt pct ZrO2/Ni-Cr and a single layer Al2O3-13 wt pct TiO2 coating deposited on low carbon steel by plasma spraying were investigated under lubricated conditions with various normal loads. The plastic deformation, detachment and pull out of splats were involved in the wear process of the studied coatings under test conditions. Crack propagation was found in Al2O3-13 wt pct TiO2 under loads of 70 and 100 N and in Al2O3-30 wt pct ZrO2/Ni-Cr under a load of 130 N.While increasing the normal load, the wear rates of Al2O3-30 wt pct ZrO2 and Al2O3-30 wt pct ZrO2/Ni-Cr slightly increased, the wear rate of Al2O3-13 wt pct TiO2 increased rapidly. The results showed that the Ni-Cr bonding layer improved the wear resistance of the coating system even it is relatively thin compared with the outer coating layer.The influence of this bonding layer on wear behavior of the coating increased as increasing the normal load.

  7. Modeling Residual Stress Development in Thermal Spray Coatings: Current Status and Way Forward

    Science.gov (United States)

    Abubakar, Abba A.; Arif, Abul Fazal M.; Al-Athel, Khaled S.; Akhtar, S. Sohail; Mostaghimi, Javad

    2017-08-01

    An overview of analytical and numerical methods for prediction of residual stresses in thermal spray coatings is presented. The various sources and mechanisms underlying residual stress development in thermal spray coatings are discussed, then the various difficulties associated with experimental residual stress measurement in thermal spray coatings are highlighted. The various analytical and numerical models used for prediction of residual stresses in thermal spray coatings are thoroughly discussed. While analytical models for prediction of postdeposition thermal mismatch stresses are fully developed, analytical quenching and peening stress models still require extensive development. Various schemes for prediction of residual stresses using the finite element method are identified. The results of the various numerical and analytical models are critically analyzed, and their accuracy and validity, when compared with experiments, are discussed. Issues regarding the accuracy and applicability of the models for predicting residual stresses in thermal spray coatings are highlighted, and several suggestions for future development of the models are given.

  8. Microstructure and Wear Properties of Fe-based Amorphous Coatings Deposited by High-velocity Oxygen Fuel Spraying

    Institute of Scientific and Technical Information of China (English)

    Gang WANG; Ping XIAO; Zhong-jia HUANG; Ru-jie HE

    2016-01-01

    Fe-based powder with a composition of Fe42·87 Cr15·98 Mo16·33 C15·94 B8·88 (at·%)was used to fabricate coatings by high-velocity oxygen fuel spraying.The effects of the spraying parameters on the microstructure and the wear properties of the Fe-based alloy coatings were systematically studied.The results showed that the obtained Fe-based coatings with a thickness of about 400μm consisted of a large-volume amorphous phase and some nanocrystals.With increasing the fuel and oxygen flow rates,the porosity of the obtained coatings decreased.The coating deposited un-der optimized parameters exhibited the lowest porosity of 2·8%.The excellent wear resistance of this coating was at-tributed to the properties of the amorphous matrix and the presence of nanocrystals homogeneously distributed with-in the matrix.The wear mechanism of the coatings was discussed on the basis of observations of the worn surfaces.

  9. Graphene based anticorrosive coatings for Cr(VI) replacement.

    Science.gov (United States)

    Aneja, Karanveer S; Bohm, Sivasambu; Khanna, A S; Bohm, H L Mallika

    2015-11-14

    Corrosion has been a perennial issue of concern for the steel industry. Chromate conversion coatings are well known pre-treatment coatings for steel but due to environmental concerns and legislations, their use has been restricted. The industrial community, pegged by these legislations, has been long demanding an economically viable and eco-friendly pre-treatment coating alternative, without having to compromise on the durability and corrosion performance of the overall coating system. The present study focuses on evaluation of graphene as an anticorrosive alternative to Cr(VI) based coatings. Graphene, produced by a high shear liquid exfoliation route, upon functionalisation, provides a conductive and nearly impermeable barrier coating. On electrochemical and coating performance evaluation of this coating system, a dramatic improvement in corrosion resistance is observed. The study confirms the environment friendly corrosion protection of steel using functionalised graphene coating.

  10. Study of Oxidation Behaviour of Bond Coating Nanocomposites Ni-20Cr-6Al Powder Synthesized by Mechanical Alloying

    Directory of Open Access Journals (Sweden)

    Akbar Salarvand

    2011-08-01

    Full Text Available In this study, nano crystalline Ni-20Cr-6Al composite powder was produced using a high energy planetary ball milling and a two-stage process. Then the oxidation behavior of coating of that superalloy at different temperatures considered. Nanostructured Ni-20Cr-6Al coating was deposited by cold spray for application as a bond coat to thermal barrier coating on industrial gas turbine components. The paper samples synthesized were characterized by scanning electron microscopy (SEM and transmission microscope (TEM. The crystallite size was found to be less than 18 nm. XRD pattern of the nanostructured Ni-20Cr-6Al milled powder consisted of two phases (Ni,Cr rich and (Ni3Al and so pure metals of Ni,Cr and Al that transferred into the coating. XRD pattern of the oxidized coating revealed that α-Al2O3 oxide was the main phase of the oxide and so Ni(Cr,Al 2O4 spinel phases despite the formation of α- Al2O3 oxide.

  11. 40 CFR 63.5755 - How do I demonstrate compliance with the aluminum recreational boat surface coating spray gun...

    Science.gov (United States)

    2010-07-01

    ... the aluminum recreational boat surface coating spray gun cleaning work practice standards? 63.5755... surface coating spray gun cleaning work practice standards? You must demonstrate compliance with the aluminum coating spray gun cleaning work practice standards by meeting the requirements of paragraph (a) or...

  12. The application of plasma-sprayed ceramic coatings on lift roller in float glass

    Institute of Scientific and Technical Information of China (English)

    2005-01-01

    Oxide ceramic was sprayed via high-energy plasma spray using MCrAlY manufactured with special technique as bond coating and oxide ceramic as top coating in this article. Investigation showed that the dense and highly adhesive coating could be obtained with optimized technique. After grinding and polishing, coating roughness was lower than 0. 2μm, which could meet the requirements of lift roller. After one year serv ice, molten Tin could not adhere to the ceramic coating,well it greatly alleviated its corrosion to the roller , kept the surface of oxide ceramic coating smooth and the improve the quality of glass due to the strengthened lift roll.

  13. Influence of the Fusing Process on the Wear and Corrosion Properties of NiCrBSi-Coatings

    Directory of Open Access Journals (Sweden)

    Evelina Roxana Secosan

    2015-07-01

    Full Text Available In this study the NiCrBSi feedstock powder was deposited by flame spraying on to C45 steel substrate. After spraying the coated material was differently fused at 1000°C. The microstructure evolution respectively the phase composition was evaluated by means of scanning electron microscopy (SEM and by X-ray diffractometry. The corrosion resistance of the differently fused coatings was assessed by potentiodynamic corrosion tests carried out in 3,5 % NaCl solution at room temperature, using a saturated calomel electrode (SCE as reference. In addition, the variation of the friction coefficients in time for the two tested coatings was determined using the pin-on-disk method. The investigations showed that the characteristics of the inductive remelted coating are better in comparison with the flame fused one.

  14. Role of process conditions on the microstructure, stoichiometry and functional performance of atmospheric plasma sprayed La(Sr)MnO3 coatings

    Science.gov (United States)

    Han, Su Jung; Chen, Yikai; Sampath, Sanjay

    2014-08-01

    Strontium doped lanthanum manganite (LSM) perovskite coatings were produced via atmospheric plasma spray technique to examine their applicability as electrically conductive coatings to protect chromium-poisoning of cathode side metallic interconnects in solid oxide fuel cells. Various plasma spray process conditions were manipulated including plasma power, total gas flow and content of H2 in the plasma gas in order to understand their effects on coating properties as well as efficacy as a protectant against Cr-poisoning. In-flight temperatures and velocities of spray particles were monitored for the various plasma spray conditions enabling assessment of thermal and kinetic energies of LSM particles. As anticipated, coating density improves with increasing thermal and/or kinetic energies of the LSM particles. However, the LSM particles also experienced significant phase decomposition at higher thermal exposure and longer residence time conditions. Due to preferential loss of oxygen and manganese, La2O3 phase is also formed under certain processing regimes. The resultant mixed-phase coating is ineffective both from electrical transport and as a protective coating for the metallic interconnect. Concomitantly, coatings with limited decomposition show excellent conductivity and protection characteristics demonstrating the need for mechanism driven process optimization for these functional oxide coatings.

  15. PHOTOCATALYTIC PERFORMANCE OF PLASMA SPRAYED TiO2-ZnFe2O4 COATINGS

    Institute of Scientific and Technical Information of China (English)

    Y. Zeng; J.T. Liu; W.J. Qian; J.H. Gao

    2005-01-01

    A novel TiO2-ZnFe2O4 coating is prepared by plasma spraying. The effects of spraying parameters and the composition of powders on the microstructure, surface morphology and photo-absorption of plasma sprayed coatings are studied. The photocatalytic efficiency of the as-sprayed coatings is evaluated through the photo mineralization of methylene blue. It was found that TiO2 coatings can decompose methylene blue under the illumination of ultraviolet rays, and the degrading efficiency is improved with an increase in the content of FeTiO3 in the coatings. However, the presence of large amount of ZnFe2O4 compound will substantially lower the photocatalytic efficiency of the TiO2-ZnFe2O4 coatings for the unfavorable photo-excited electron-hole transfer process.

  16. The effect of coating residual stress on the fatigue life of thermal spray-coated steel and aluminum

    Energy Technology Data Exchange (ETDEWEB)

    McGrann, R.T.R.; Greving, D.J.; Shadley, J.R.; Rybicki, E.F. [Tulsa Univ., OK (United States). Mechanical Engineering Dept.; Kruecke, T.L.; Bodger, B.E. [Southwest Aeroservice, Inc., Tulsa, OK (United States)

    1998-10-10

    The acceptance of thermal spray coatings in many applications depends on the effect of the coating on the fatigue performance of the coated part. One of the factors that influences the fatigue life of thermal spray-coated components is the residual stress in the coating. This study investigates the fatigue performance of tungsten carbide-cobalt (WC-Co) thermal spray coating systems. Bending fatigue tests of specimens with WC-Co coatings on both 4130 steel substrates and 6061 aluminum substrates were conducted. The through-thickness residual stress level in the thermal spray coatings was determined using the modified layer removal method. The effect of the residual stresses on the fatigue life of the coated specimens was analyzed. It was found that there is a direct relation between the residual stress in the coating and the fatigue life of the coated part. Fatigue life can be changed by a factor of ten due to the level of compressive residual stress in the coating. (orig.) 7 refs.

  17. Wear Micro-Mechanisms of Composite WC-Co/Cr - NiCrFeBSiC Coatings. Part I: Dry Sliding

    Directory of Open Access Journals (Sweden)

    D. Kekes

    2014-12-01

    Full Text Available The influence of the cermet fraction in cermet/ metal composite coatings developed by High-Velocity Oxyfuel Flame (HVOF spraying on their tribological behaviour was studied. Five series of coatings, each one containing different proportion of cermet-metal components, prepared by premixing commercially available feedstocks of NiCrFeBSiC metallic and WC-Co/Cr cermet powders were deposited on AISI 304 stainless steel substrate. The microstructure of as-sprayed coatings was characterized by partial decomposition of the WC particles, lamellar morphology and micro-porosity among the solidified splats. Tribological behavior was studied under sliding friction conditions using a Si3N4 ball as counterbody and the friction coefficient and volume loss were determined as a function of the cermet fraction. Microscopic examinations of the wear tracks and relevant cross sections identified the wear mechanisms involved. Coatings containing only the metallic phase were worn out through a combination of ploughing, micro-cracking and splat exfoliation, whilst those containing only the cermet phase primarily by micro-cracking at the individual splat scale. The wear mechanisms of the composite coatings were strongly affected by their randomly stratified structure. In-depth cracks almost perpendicular to the coating/ substrate interface occurring at the wear track boundaries resulted in cermet trans-splat fracture.

  18. Improving osseointegration of Co-Cr by nanostructured titanium coatings.

    Science.gov (United States)

    Pham, Vuong-Hung

    2014-01-01

    This study reports the deposition of nanostructured Ti films on Co-Cr substrates to improve their surface characteristics and biocompatibility. The microstructure of the Ti films was controlled by application of negative substrate bias voltages. The surface roughness of Co-Cr implants was increased significantly after Ti coatings. The nanostructured Ti films are found to improve osteointergration of Co-Cr implants as indicated by enhancing cellular attachment, proliferation and differentiation, which was attributed mainly to the application of a biocompatible Ti coating, possessed a higher surface area for cell attachments and growth.

  19. The erosion performance of particle reinforced metal matrix composite coatings produced by co-deposition cold gas dynamic spraying

    Science.gov (United States)

    Peat, Tom; Galloway, Alexander; Toumpis, Athanasios; McNutt, Philip; Iqbal, Naveed

    2017-02-01

    This work reports on the erosion performance of three particle reinforced metal matrix composite coatings, co-deposited with an aluminium binder via cold-gas dynamic spraying. The deposition of ceramic particles is difficult to achieve with typical cold spray techniques due to the absence of particle deformation. This issue has been overcome in the present study by simultaneously spraying the reinforcing particles with a ductile metallic binder which has led to an increased level of ceramic/cermet particles deposited on the substrate with thick (>400 μm) coatings produced. The aim of this investigation was to evaluate the erosion performance of the co-deposited coatings within a slurry environment. The study also incorporated standard metallographic characterisation techniques to evaluate the distribution of reinforcing particles within the aluminium matrix. All coatings exhibited poorer erosion performance than the uncoated material, both in terms of volume loss and mass loss. The Al2O3 reinforced coating sustained the greatest amount of damage following exposure to the slurry and recorded the greatest volume loss (approx. 2.8 mm3) out of all of the examined coatings. Despite the poor erosion performance, the WC-CoCr reinforced coating demonstrated a considerable hardness increase over the as-received AA5083 (approx. 400%) and also exhibited the smallest free space length between adjacent particles. The findings of this study reveal that the removal of the AA5083 matrix by the impinging silicon carbide particles acts as the primary wear mechanism leading to the degradation of the coating. Analysis of the wear scar has demonstrated that the damage to the soft matrix alloy takes the form of ploughing and scoring which subsequently exposes carbide/oxide particles to the impinging slurry.

  20. Bonelike apatite coatings on plasma-sprayed porous titanium by biomimetic processing

    Institute of Scientific and Technical Information of China (English)

    SHI Jian-min; DING Chuan-xian

    2001-01-01

    @@ INTRODUCTION Hydroxyapatite (HA) has many biological benefits, such as direct bonding to bone and enhances new bone formation around it. It has been demonstrated that dental and orthopaedic implants coated with HA show superior histological results to the uncoated ones. Various methods as well as plasma spraying, which is commonly used, have been developed to coat HA on metals. However, Plasma-sprayed HA coatings are limited by specific drawbacks such as low crystallinity, weak bond strength to the substrate.

  1. Determination of parameters for successful spray coating of silicon microneedle arrays.

    Science.gov (United States)

    McGrath, Marie G; Vrdoljak, Anto; O'Mahony, Conor; Oliveira, Jorge C; Moore, Anne C; Crean, Abina M

    2011-08-30

    Coated microneedle patches have demonstrated potential for effective, minimally invasive, drug and vaccine delivery. To facilitate cost-effective, industrial-scale production of coated microneedle patches, a continuous coating method which utilises conventional pharmaceutical processes is an attractive prospect. Here, the potential of spray-coating silicon microneedle patches using a conventional film-coating process was evaluated and the key process parameters which impact on coating coalescence and weight were identified by employing a fractional factorial design to coat flat silicon patches. Processing parameters analysed included concentration of coating material, liquid input rate, duration of spraying, atomisation air pressure, gun-to-surface distance and air cap setting. Two film-coating materials were investigated; hydroxypropylmethylcellulose (HPMC) and carboxymethylcellulose (CMC). HPMC readily formed a film-coat on silicon when suitable spray coating parameter settings were determined. CMC films required the inclusion of a surfactant (1%, w/w Tween 80) to facilitate coalescence of the sprayed droplets on the silicon surface. Spray coating parameters identified by experimental design, successfully coated 280μm silicon microneedle arrays, producing an intact film-coat, which follows the contours of the microneedle array without occlusion of the microneedle shape. This study demonstrates a novel method of coating microneedle arrays with biocompatible polymers using a conventional film-coating process. It is the first study to indicate the thickness and roughness of coatings applied to microneedle arrays. The study also highlights the importance of identifying suitable processing parameters when film coating substrates of micron dimensions. The ability of a fractional factorial design to identify these critical parameters is also demonstrated. The polymer coatings applied in this study can potentially be drug loaded for intradermal drug and vaccine delivery

  2. Scalable nanomanufacturing of surfactant-free carbon nanotube inks for spray coatings with high conductivity

    Institute of Scientific and Technical Information of China (English)

    Colin Preston[1; Da Song[1; Jaiqi Dai[1; Zois Tsinas[2; John Bavier[3; John Cumings[1; Vince Ballarotto[3; Liangbing Hu[1

    2015-01-01

    Spray-coated carbon nanotube films offer a simple and printable solution for fabricating low cost, lightweight, and flexible thin-film electronics. However, current nanotube spray inks require either a disruptive surfactant or destructive surface functionalization to stabilize dispersions at the cost of the electrical properties of the deposited film. We demonstrate that high-purity few-walled carbon nanotubes may be stabilized in isopropanol after surface functionalization and that optimizing the ink stability dramatically enhances the conductivity of subsequent spray-coated thin films. We consequently report a surfactant-free carbon nanotube ink for spray-coated thin films with conductivities reaching 2,100 S/cm. Zeta-potential measurements, used to quantify the nanotube ink dispersion quality, directly demonstrate a positive correlation with the spray- coated film conductivity, which is the key metric for high-performance printed electronics.

  3. Indentation creep behavior of cold sprayed aluminum amorphous/nano-crystalline coatings

    Energy Technology Data Exchange (ETDEWEB)

    Babu, P. Suresh [International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), Balapur, Hyderabad 500005, Andhra Pradesh (India); Nanomechanics and Nanotribology Laboratory, Department of Mechanical and Materials Engineering, Florida International University, Miami, FL 33174 (United States); Jha, R.; Guzman, M. [Nanomechanics and Nanotribology Laboratory, Department of Mechanical and Materials Engineering, Florida International University, Miami, FL 33174 (United States); Sundararajan, G. [International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), Balapur, Hyderabad 500005, Andhra Pradesh (India); Agarwal, Arvind, E-mail: agarwala@fiu.edu [Nanomechanics and Nanotribology Laboratory, Department of Mechanical and Materials Engineering, Florida International University, Miami, FL 33174 (United States)

    2016-03-21

    In this study, we report room temperature creep properties of cold sprayed aluminum amorphous/nanocrystalline coating using nanoindentation technique. Creep experiments were also performed on heat treated coatings to study the structural stability and its influence on the creep behavior. The peak load and holding time were varied from 1000 to 4000 µN and 0 to 240 s respectively. Stress exponent value (n) vary from 5.6 to 2.3 in as-sprayed (AS) coatings and 7.2–4.8 in heat treated (HT) coatings at peak load of 1000–4000 µN at 240 s hold time. Higher stress exponent value indicates heat treated coatings have more resistance to creep deformation than as-sprayed coatings. Relaxed, partially crystallized structure with less porosity, and stronger inter-splat boundaries restrict the deformation in heat treated coatings as compared to greater free volume generation in amorphous as-sprayed coatings. The computed activation volume of heat treated coatings is twice of as-sprayed coatings indicating greater number of atom participation in shear band formation in heat treated coatings. The proposed mechanism was found to be consistent with the stress exponent values.

  4. Salt spray corrosion test of micro-plasma oxidation ceramic coatings on Ti alloy

    Institute of Scientific and Technical Information of China (English)

    2007-01-01

    Ceramic coatings were prepared on Ti-6Al-4V alloy in NaAlO2 solution by micro-plasma oxidation (MPO). The salt spray teste of tne coated samples and the substrates were carried out in a salt spray test machine. The phase composition and surface morphology of the coatings were investigated by XRD and SEM. Severe corrosion occurred on the substrate surface, while there were no obvious corrosion phenomena on the coated samples. The coatings were composed of Al2TiO5 and a little α-Al2O3 and rutile TiO2, and the salt spray test did not change the composition of the coatings. The weight loss rate of the coatings decreased with increasing MPO time because of the increase in density and thickness of the coatings. The surface morphology of the coatings was influenced by salt spray corrosion test Among the coated samples, the coating prepared for 2 h has the best corrosion resistance under salt spray test.

  5. Highly Segmented Thermal Barrier Coatings Deposited by Suspension Plasma Spray: Effects of Spray Process on Microstructure

    Science.gov (United States)

    Chen, Xiaolong; Honda, Hiroshi; Kuroda, Seiji; Araki, Hiroshi; Murakami, Hideyuki; Watanabe, Makoto; Sakka, Yoshio

    2016-12-01

    Effects of the ceramic powder size used for suspension as well as several processing parameters in suspension plasma spraying of YSZ were investigated experimentally, aiming to fabricate highly segmented microstructures for thermal barrier coating (TBC) applications. Particle image velocimetry (PIV) was used to observe the atomization process and the velocity distribution of atomized droplets and ceramic particles travelling toward the substrates. The tested parameters included the secondary plasma gas (He versus H2), suspension injection flow rate, and substrate surface roughness. Results indicated that a plasma jet with a relatively higher content of He or H2 as the secondary plasma gas was critical to produce highly segmented YSZ TBCs with a crack density up to 12 cracks/mm. The optimized suspension flow rate played an important role to realize coatings with a reduced porosity level and improved adhesion. An increased powder size and higher operation power level were beneficial for the formation of highly segmented coatings onto substrates with a wider range of surface roughness.

  6. Production of Nanocrystalline Ni-20Cr Coatings for High-Temperature Applications

    Science.gov (United States)

    Kumar, Manoj; Singh, Harpreet; Singh, Narinder

    2014-04-01

    Presynthesized nanocrystalline Ni-20Cr powder was deposited on SA 516 and T91 boiler steels by a high-velocity oxy-fuel spraying process. Ni-20Cr powder was synthesized by the ball milling approach. The high-temperature oxidation behavior of bare and coated samples was then studied under cyclic isothermal conditions at 900 °C for 50 cycles. The kinetics of oxidation was established using weight change measurements for the bare and coated boiler steels. Uncoated and coated samples of T91 steel were exposed to the superheated zone of a power plant boiler at 750 °C under cyclic conditions for 15 cycles. Each cycle consisted of 100 h of heating followed by 1 h of cooling. Attempts were made to study the kinetics of erosion-corrosion using weight change and thickness loss data for the samples. Different characterization techniques were used to study the oxidized and eroded-corroded samples, including x-ray diffraction, scanning electron microscopy/energy-dispersive spectroscopy, and x-ray mapping analyses. The Ni-20Cr alloy powder coating was found to offer excellent oxidation resistance to the base steels and was successful in reducing the weight gain of SA 516 steel by 98.5 % and that of T91 steel by 65 %. The coating was observed to reduce the erosion-corrosion rate of T91 steel by 86 % in terms of thickness loss. This indicates that the investigated nanostructured coating can be a better choice over conventional coating for erosion-corrosion control of boiler tubes.

  7. Tribological properties of nanostructured n-Al2O3/Ni coatings deposited by plasma spraying

    Institute of Scientific and Technical Information of China (English)

    LI Chang-qing; MA Shi-ning; YE Xiong-lin

    2005-01-01

    Nanostructured n-Al2 Os/Ni feedstock for thermal spraying was manufactured by the method of chemical wrapping and spray drying. The nanostructured coating was sprayed with this feedstock. Tribological properties ofthe coatings and steel 45# were tested. Within the testing range, the friction coefficient of coatings against GCr15 steel decreased and the mass loss of coatings increased at first then decreased with the increase of load. Under each load, the coatings' friction coefficients and wear losses were lower than that of steel 45 # . Scanning electron micros copy and energy dispersive spectrometer analysis show that adhesion is the dominating wear mechanism, and fatigue exists at the same time. Material transferred from counter-part to the coating is the main factor which influences the coatings' friction coefficient and wear losses.

  8. Hot spray technology of TA7 titanium alloy coated by molybdenum and its bonding strength

    Institute of Scientific and Technical Information of China (English)

    Li Xiaoquan; Du Zeyu; Yang Xuguang

    2006-01-01

    A kind of surface modification test was introduced, by which plasma spray in argon atmosphere with CNC4500 system was applied for TA7 titanium alloy to be coated with molybdenum, and technology to produce metallurgical bonding at interface of coating and base meal was tested by heating in vacuum condition for diffusion after hot spray.With the help of scan electron microscope analysis ( SEM) , the effect of argon inlet pressure and heating temperature on coating structure as well as product of diffusion layer were studied.The glued tensile test method was used to measure bonding strength of base metal to coating.The result has shown that both argon inlet pressure and heating temperature exert some effect on coating structure and the width of diffusion layer.A bonding strength of base metal to coating which is greater than molybdenum coating itself may be attained and can be controlled in more than 50 MPa level with tested hot spray technology.

  9. Preparation and Characterization of Plasma-Sprayed Ultrafine Chromium Oxide Coatings

    Institute of Scientific and Technical Information of China (English)

    LIN Feng; JIANG Xianliang; YU Yueguang; ZENG Keli; REN Xianjing; LI Zhenduo

    2007-01-01

    Ultrafine chromium oxide coatings were prepared by plasma spraying with ultrafine feedstock. Processing parameters of plasma spraying were optimized. Optical microscope (OM) was used to observe the microstructure of the ultrafine chromium oxide coatings. Scanning electron microscopy (SEM) was used to observe the morphology and particle size of ultrafine powder feedstock as well as to examine the microstructure of the chromium oxide coating. In addition, hardness and bonding strength of the ultrafine chromium oxide coatings were measured.The results showed that the optimized plasma spraying parameters were suitable for ultrafine chromium oxide coating and the properties and microstructure of the optimized ultrafine chromium oxide coating were superior compared to conventional chromium oxide wear resistant coatings.

  10. Bioactive Glass-Ceramic Coatings Synthesized by the Liquid Precursor Plasma Spraying Process

    Science.gov (United States)

    Xiao, Yanfeng; Song, Lei; Liu, Xiaoguang; Huang, Yi; Huang, Tao; Chen, Jiyong; Wu, Yao; Wu, Fang

    2011-03-01

    In this study, the liquid precursor plasma spraying process was used to manufacture P2O5-Na2O-CaO-SiO2 bioactive glass-ceramic coatings (BGCCs), where sol and suspension were used as feedstocks for plasma spraying. The effect of precursor and spray parameters on the formation and crystallinity of BGCCs was systematically studied. The results indicated that coatings with higher crystallinity were obtained using the sol precursor, while nanostructured coatings predominantly consisting of amorphous phase were synthesized using the suspension precursor. For coatings manufactured from suspension, the fraction of the amorphous phase increased with the increase in plasma power and the decrease in liquid precursor feed rate. The coatings synthesized from the suspension plasma spray process also showed a good in vitro bioactivity, as suggested by the fast apatite formation when soaking into SBF.

  11. Pack cementation Cr-Al coating of steels and Ge-doped silicide coating of Cr-Nb alloy

    Energy Technology Data Exchange (ETDEWEB)

    He, Y.R.; Zheng, M.H.; Rapp, R.A. [Ohio State Univ., Columbus, OH (United States)

    1995-08-01

    Carbon steels or low-alloy steels used in utility boilers, heat exchangers, petrochemical plants and coal gasification systems are subjected to high temperature corrosion attack such as oxidation, sulfidation and hot corrosion. The pack cementation coating process has proven to be an economical and effective method to enhance the corrosion resistance by modifying the surface composition of steels. With the aid of a computer program, STEPSOL, pack cementation conditions to produce a ferrite Cr-Al diffusion coating on carbon-containing steels by using elemental Cr and Al powders have been calculated and experimentally verified. The cyclic oxidation kinetics for the Cr-Al coated steels are presented. Chromium silicide can maintain high oxidation resistance up to 1100{degrees}C by forming a SiO{sub 2} protective scale. Previous studies at Ohio State University have shown that the cyclic oxidation resistance of MOSi{sub 2} and TiSi{sub 2} can be further improved by Ge addition introduced during coating growth. The halide-activated pack cementation process was modified to produce a Ge-doped silicide diffusion coating in a single processing step for the ORNL-developed Cr-Nb advanced intermetallic alloy. The oxidation behavior of the silicide-coated Cr-Nb alloy was excellent: weight gain of about 1 mg/cm{sup 2} upon oxidation at 1100{degrees}C in air for 100 hours.

  12. Performance of high-velocity oxy-fuel-sprayed chromium carbide-nickel chromium coating in an actual boiler environment of a thermal power plant

    Energy Technology Data Exchange (ETDEWEB)

    Sidhu, T.S.; Prakash, S.; Agrawal, R.D. [Industrial Technology Institute, Roorkee (India)

    2007-09-15

    The present study aims to evaluate the performance of a high-velocity oxy-fuel (HVOF)-sprayed Cr{sub 3}C{sub 2}-NiCr (chromium carbide-nickel chromium) coating on a nickel-based super-alloy in an actual industrial environment of a coal-fired boiler, with the objective to protect the boiler super-heater and reheater tubes from hot corrosion. The tests were performed in the platen super heater zone of a coal-fired boiler for 1,000 h at 900 degrees C under cyclic conditions. The Cr{sub 3}C{sub 2}-NiCr coating imparted the necessary protection to the nickel-based super alloy in the given environment. The dense and flat splat structure of the coating, and the formation of oxides of chromium and nickel and their spinels, might have protected the substrate super alloy from the inward permeation of corrosive species.

  13. Preliminary Microstructural and Microscratch Results of Ni-Cr-Fe and Cr3C2-NiCr Coatings on Magnesium Substrate

    Science.gov (United States)

    Istrate, B.; Munteanu, C.; Lupescu, S.; Benchea, M.; Vizureanu, P.

    2017-06-01

    Thermal coatings have a large scale application in aerospace and automotive field, as barriers improving wear mechanical characteristics and corrosion resistance. In present research, there have been used two types of coatings, Ni-Cr-Fe, respectively Cr3C2-NiCr which were deposited on magnesium based alloys (pure magnesium and Mg-30Y master alloy). There have been investigated the microstructural aspects through scanning electronic microscopy and XRD analysis and also a series of mechanical characteristics through microscratch and indentation determinations. The results revealed the formation of some adherent layers resistant to the penetration of the metallic indenter, the coatings did not suffer major damages. Microstructural analysis highlighted the formation of Cr3C2, Cr7C3, Cr3Ni2, Cr7Ni3, FeNi3, Cr-Ni phases. Also, the apparent coefficient of friction for Ni-Cr-Fe coatings presents superior values than Cr3C2-NiCr coatings.

  14. Formation of hydrotalcite coating on the aluminum alloy 6060 in spray system

    DEFF Research Database (Denmark)

    Zhou, Lingli; Friis, Henrik; Roefzaad, Melanie

    2016-01-01

    -layer structure with average thickness of ∼1000 nm. The hydrotalcite-coated samples performed better than those without coatings in salt-spray and filiform-corrosion tests, and further treatment involving sealing with a Mg acetate solution and dipping in a H2O2 + Ce-based solution improved the corrosion......Coatings with the composition of Li-Al-NO3 hydrotalcite were formed on the Al alloy 6060 using a spray system. The coatings consist of crystals with a typical hydrotalcite structure. Dense, uniform and blade-like flakes cover completely the surface of the Al substrate. The coatings display a multi...

  15. Atmosphere corrosion behavior of plasma sprayed and laser remelted coatings on copper

    Institute of Scientific and Technical Information of China (English)

    Gongying Liang; T. T. Wong; Geng An; J. M. K. MacAlpine

    2006-01-01

    Nickel and chromium coatings were produced using plasma spraying and laser remelting on the copper sheet. The corrosion test was carried out in an acidic atmosphere, and the corrosive behaviors of both coatings and original copper samples were investigated by using an impedance comparison method. Experimental results show that nickel and chromium coatings display better corrosion resistance properties relative to the original pure copper sample. The corrosion rate of chromium coating is less than that of nickel coating, and corrosion resistances of laser remelted nickel and chromium samples are better thanthose of plasma sprayed samples. The corrosion deposit film of copper is loose compared with nickel and chromium.

  16. Sprayed and Spin-Coated Multilayer Antireflection Coating Films for Nonvacuum Processed Crystalline Silicon Solar Cells

    Directory of Open Access Journals (Sweden)

    Abdullah Uzum

    2017-01-01

    Full Text Available Using the simple and cost-effective methods, spin-coated ZrO2-polymer composite/spray-deposited TiO2-compact multilayer antireflection coating film was introduced. With a single TiO2-compact film on the surface of a crystalline silicon wafer, 5.3% average reflectance (the reflectance average between the wavelengths of 300 nm and 1100 nm was observed. Reflectance decreased further down to 3.3% after forming spin-coated ZrO2 on the spray-deposited TiO2-compact film. Silicon solar cells were fabricated using CZ-Si p-type wafers in three sets: (1 without antireflection coating (ARC layer, (2 with TiO2-compact ARC film, and (3 with ZrO2-polymer composite/TiO2-compact multilayer ARC film. Conversion efficiency of the cells improved by a factor of 0.8% (from 15.19% to 15.88% owing to the multilayer ARC. Jsc was improved further by 2 mA cm−2 (from 35.3 mA cm−2 to 37.2 mA cm−2 when compared with a single TiO2-compact ARC.

  17. Characterization of functionally graded ZrO2 thermal barrier coatings sprayed by supersonic plasma spray with dual powder feed ports

    Institute of Scientific and Technical Information of China (English)

    HAN Zhi-hai; WANG Hai-jun; ZHOU Shi-kui; XU Bing-shi

    2005-01-01

    The functionally graded thermal barrier coatings (FG-TBCs) with 80 % ZrO2-13 % CeO2-7 % Y2 Os ( CYSZ)/NiCoCrAlY were prepared using a recently developed supersonic plasma spraying(S-PS) with dual powder feed ports system. The thermal shock experiment of FG-TBCs specimens was carried out by means of the automatic thermal cycle device, in which the samples were heated to 1 200 ℃ by oxygen-acetylene flame jet then waterquenched to ambient temperature. The temperature-time curves of specimens and photographs can be watched online and recorded by a computer during the test. The results show that the totally 1 mm-thick FG-TBCs have excellent thermal shock resistance due to the fact that the coatings have no any peeling-off after 200 thermal cycles. The microstructures and morphologies of FG-TBCs were characterized and analyzed by SEM.

  18. Effects of Spray Parameters and Post-spray Heat Treatment on Microstructure and Mechanical Properties of Warm-Sprayed Ti-6Al-4V Coatings

    Science.gov (United States)

    Molak, R. M.; Araki, H.; Watanabe, M.; Katanoda, H.; Ohno, N.; Kuroda, S.

    2016-12-01

    Warm spray is a novel thermal spray technique that allows the formation of dense and relatively pure Ti-6Al-4V coatings due to its capability to control the temperature of the propellant gas by diluting the combustion flame with an inert gas such as nitrogen. Recently, its combustion pressure has been increased from 1 to 4 MPa aiming to further increase particle velocity to over 1000 m/s. Two series of coatings with combustion pressure of 1 and 4 MPa and various nitrogen flow rates were prepared in this study. Effects of combustion pressure and nitrogen flow rate on the microstructure and mechanical properties of the Ti-6Al-4V coatings were systematically studied. Miniature tensile specimens with a total length of about 9 mm were used for static tensile tests. It was found that the spray parameters affect both the porosity and oxygen content of the coatings significantly and had remarkable effects on their mechanical properties. High level of porosity in the Ti-6Al-4V coatings reduced the effective cross-sectional area of the mini-specimens and caused a drop in their tensile strength and Young's modulus. Subsequent heat treatments were found effective in significantly recovering the mechanical properties of the as-sprayed coatings.

  19. Dry friction aspects of Ni-based self-fluxing flame sprayed coatings

    Science.gov (United States)

    Paulin, C.; Chicet, D.; Paleu, V.; Benchea, M.; Lupescu, Ş.; Munteanu, C.

    2017-08-01

    In this paper we present the results tribological obtained in the course of dry wear tests on samples coated with three types of coatings produced from self-fluxing Ni-based powders. In this purpose were used three commercial NiCrBSi powders produced by various manufacturers, which have been sprayed against a low alloyed steel substrate using the flame spray thermal deposition method followed by flame remelting, resulting three different samples, denoted as: A, M and P. The first test was conducted on an Amsler type machine, with rolling motion between tribological contacts of third class. The analysed coating was deposited on the generator of the low alloy steel disc and the shoe was realized from a grindstone. The test was conducted for two situations: (a) constant load of 10 kg and 6 kg applied for 5 hours; (b) progressive load starting from 2 to 10 kg for two different speeds of rotation of the disc. The second test was the one of sliding wear and it was conducted on the UMTR 2M-CTR tribometer. The analysed layers were deposited on the flat surface of a low alloy steel lamella, and the friction was achieved with a conical grinding stone. The working parameters were as follows: 20N constant load, constant speed of 10 mm / s, sliding linear length of 30mm, the test duration being 45 minutes. After conducting the tests and after analysing the results, the following conclusions are drawn: a) during the first test has been obtained a global friction coefficient between 0.3 and 0.4 - typical for dry friction, highlighting some lower values in the case of sample A, in which case there were recorded smaller mass losses; b) at the second test was recorded an approximately linear behaviour of the three samples, with a gradual increase of the friction coefficient and a superficial wear mark revealed both by SEM microscopy and by profilometry.

  20. Formation of hydrotalcite coating on the aluminum alloy 6060 in spray system

    DEFF Research Database (Denmark)

    Zhou, Lingli; Friis, Henrik; Roefzaad, Melanie

    2016-01-01

    Coatings with the composition of Li-Al-NO3 hydrotalcite were formed on the Al alloy 6060 using a spray system. The coatings consist of crystals with a typical hydrotalcite structure. Dense, uniform and blade-like flakes cover completely the surface of the Al substrate. The coatings display a mult...

  1. THE POTENTIAL VALUE OF PHOTOTHERMAL IMAGING FOR THE TESTING OF PLASMA SPRAYED COATINGS

    OpenAIRE

    Almond, D.; Patel, P; Reiter, H.

    1983-01-01

    Measurements are presented which show that the photothermal technique may be used to evaluate plasma sprayed coatings. A photothermal image of a coating adhesion defect is shown and changes in photothermal signal with coating thickness are demonstrated. These measurements are compared directly with ultrasonic measurements of the same sample.

  2. Combined slurry and cavitation erosion resistance of HVOF spray coated SS 410 steel

    Science.gov (United States)

    Amarendra, H. J.; Prathap, M. S.; Karthik, S.; Abhishek, A. M.; Madhu surya, K. C.; Gujjar gowda, S.; Anilkumar, T.

    2016-09-01

    The hydro turbine materials surface is degraded due to the slurry erosion and cavitation. The solid particles carried by water impacting the material results in slurry erosion. The damage occurred due to slurry erosion is the concern, when considered individually. The erosion damage is observed to be severe when slurry erosion and cavitation are combined. The hydro turbine material, martensitic stainless (SS 410) is surface modified with 80Ni-Cr by High Velocity Oxy Fuel spray process. The coated material subjected to post thermal treatment at a temperature of 950 ° C, soaked at 1 h, 2 h and 3 h are subjected to combined slurry and cavitation erosion test. The cavitation is created by using Cavitation Inducers. The tests are conducted by using silica sand as the erodent with three different sizes of 150, 200 and 300 μm. The results are compared with the as-received specimen. The results confirmed the effect of heat treatment on the end results, as the coated thermal treated specimens showed better erosion resistance against the as-received specimen. The eroded specimens are characterized by Scanning Electron Microscope. The thermal treated HVOF coated specimens shown the better erosion resistance.

  3. Hot Corrosion Studies of HVOF-Sprayed Coating on T-91 Boiler Tube Steel at Different Operating Temperatures

    Science.gov (United States)

    Bhatia, Rakesh; Singh, Hazoor; Sidhu, Buta Singh

    2013-11-01

    The aim of the present work is to investigate the usefulness of high velocity oxy fuel-sprayed 75% Cr3C2-25% (Ni-20Cr) coating to control hot corrosion of T-91 boiler tube steel at different operating temperatures viz 550, 700, and 850 °C. The deposited coatings on the substrates exhibit nearly uniform, adherent and dense microstructure with porosity less than 2%. Thermogravimetry technique is used to study the high temperature hot corrosion behavior of uncoated and coated samples. The corrosion products of the coating on the substrate are analyzed by using XRD, SEM, and FE-SEM/EDAX to reveal their microstructural and compositional features for the corrosion mechanisms. It is found that the coated specimens have shown minimum weight gain at all the operating temperatures when compared with uncoated T-91 samples. Hence, coating is effective in decreasing the corrosion rate in the given molten salt environment. Oxides and spinels of nickel-chromium may be the reason for successful resistance against hot corrosion.

  4. Abrasive Wear Behavior of WC Reinforced Ni-BASED Composite Coating Sprayed and Fused by Oxy-Acetylene Flame

    Science.gov (United States)

    Wang, Qun; Chen, Zhenhua; Ding, Zhang Xiong; Chen, Ding

    Microstructure of WC reinforced Ni-based self-fluxing alloy composite coating sprayed and fused by oxy-acetylene flame was investigated by scanning electron microscopy and energy dispersive X-ray Spectrometry, X-ray diffraction, and transmission electron microscopy. The wear performance of the coating was studied by a MLS-225 wet sand rubber wheel abrasive wear tester at various loads and sizes of abrasive particles. Also, the wear resistance of the coating was compared with uncoated ASTM1020 steel. The results indicated that the coating is bonded metallurgically to the substrate and has a homogeneous microstructure composed of both coarse WC and fine carbide and boride grains such as Cr7C3, Cr23C6, and Ni2B which disperse uniformly in the matrix of γ-Ni solid solution and Ni3B. The worn mass loss of the coating and ASTM1020 steel both increased with the load and size of abrasive particles, also, the coating has exhibited excellent abrasive wear resistance compared with ASTM1020 steel.

  5. Wear and Corrosion Resistance of Fe Based Coatings by HVOF Sprayed on Gray Cast-Iron for Automotive Application

    Directory of Open Access Journals (Sweden)

    M.S. Priyan

    2014-12-01

    Full Text Available In this study, commercially available FeSiNiCr and FeBCr alloy powders were designed with suitable compositions, gas atomized and then coated on gray cast-iron substrate. The microstructures of the feed stock Fe based alloy powders and the coatings were investigated by means of optical microscopy (OM, X-Ray diffraction (XRD, Thermogravimetric analysis (TGA and Scanning Electron Microscopy (SEM. In the present study, both the coating materials experienced two-body wear mechanisms. The results showed that for loads of 0.05 N, 0.1 N and 0.2 N, the wear resistance of FeBCr coating was less than FeSiNiCr by 44 %, 40 % and 31 %, respectively. The results indicated that the coated substrates exhibited lower corrosion current densities and lower corrosion rates, when placed in 20 wt.% H2SO4 solutions. In addition, the use of optimal spraying parameters/conditions gave improvements to the corrosion resistance of the substrates that had been treated with the crystalline coating.

  6. MICROSTRUCTURE OF CR2O3 COATINGS ON STEEL AND THE EFFECT OF SILICON

    NARCIS (Netherlands)

    VANDENBURG, M; DEHOSSON, JTM; Burg, M. van den

    This paper concentrates on the microstructural features of steel containing 22 wt.% Cr, coated with Cr2O3 by laser processing. It turned out that after laser coating the Cr2O3 powder has completely transformed to Fe0.3Cr2.7O4 having the tetragonal distorted spinel structure. Dispersed in the coating

  7. MICROSTRUCTURE OF CR2O3 COATINGS ON STEEL AND THE EFFECT OF SILICON

    NARCIS (Netherlands)

    VANDENBURG, M; DEHOSSON, JTM; Burg, M. van den

    1994-01-01

    This paper concentrates on the microstructural features of steel containing 22 wt.% Cr, coated with Cr2O3 by laser processing. It turned out that after laser coating the Cr2O3 powder has completely transformed to Fe0.3Cr2.7O4 having the tetragonal distorted spinel structure. Dispersed in the coating

  8. Mehanička svojstva i mikrostruktura vakuum plazma naprskane Cr3C2 - 25(Ni20Cr prevlake / Mechanical properties and microstructure of vacuum plasma sprayed Cr3C2 – 25(Ni20Cr coatings / Механические свойства и микроструктура покрытия Cr3C2 - 25(Ni20Cr нанесенного методом вакуумного плазменного напыления

    Directory of Open Access Journals (Sweden)

    Mihailo R. Mrdak

    2015-04-01

    Full Text Available U radu je analizirana vakuum plazma sprej prevlaka VPS – Cr3C2 - 25(Ni20Cr. Upotrebljen je komercijalni prah oznake Sulzer Metco Woka 7205. Prah je deponovan sa plazma pištoljem F4 na odstojanju substrata od 340 mm. Glavni cilj rada bio je da se na smanjenom pritisku inertnog gasa Ar eliminiše razgradnja primarnog karbida Cr3C2 u karbid Cr23C6 koji bitno umanjuje mikrotvrdoću i mehaničke karakteristike prevlake. Prevlaka je deponovana debljine od 100 do 120 µm na čeličnom substratu. Mikrotvrdoća prevlake ispitana je metodom HV0.3. Vrednosti mikrotvrdoće bile su u rasponu od 1248 do 1342 HV0.3. Čvrstoća spoja prevlake ispitana je metodom na zatezanje. Utvrđeno je da čvrstoća spoja između substrata i prevlake ima vrednost 89 MPa. Mikrostruktura prevlake ispitana je tehnikom svetlosne mikroskopije. Struktura prevlake sastoji se od osnove NiCr legure sa dominantnom primarnom karbidnom fazom Cr3C2. Pored Cr3C2 faze prisutna je i faza Cr7C3. Nagrizanje prevlake urađeno je reagensom 1HNO3: 4HCl: 4H2O koji prvenstveno rastvara Ni da bi se videla raspodela karbidne faze u prevlaci. Nagrizanjem prevlake reagensom utvrđeno je da je u slojevima prevlake u velikom udelu prisutna primarna nerazgrađena karbidna faza Cr3C2 koja prevlaci daje visoke vrednosti mikrotvrdoće. / This paper analyzes vacuum plasma spray VPS - Cr3C2 - 25(Ni20Cr coatings. Commercial powder marked Sulzer Metco Woka 7205 is used. The powder is deposited with a plasma gun F4 at a distance of 340 mm from the substrate. The main objective of the study was to eliminate, at the reduced pressure of inert gas Ar, the degradation of primary Cr3C2 carbide into Cr23C6 carbide which significantly reduces the microhardness and mechanical properties of the coating. The coating is deposited with a thickness of 100 - 120 µm on a steel substrate. The microhardness of the coating was tested by HV0.3. The microhardness values were in the range of 1248 - 1342 HV0.3. The bond strength

  9. Physical chemistry of WC-12 %Co coatings deposited by thermal spraying at different standoff distances

    Energy Technology Data Exchange (ETDEWEB)

    Afzal, Muhammad; Ahmed, Furqan; Anwar, Muhammad Yousaf; Ali, Liaqat; Ajmal, Muhammad [Univ. of Engineering and Technology, Metallurgical and Materials Engineering, Lahore (Pakistan); Khan, Aamer Nusair [Institute of Industrial and Control System, Rawalpindi (Pakistan)

    2015-09-15

    In the present research, WC-12 %Co cermet coatings were deposited on AISI-321 stainless steel substrate using air plasma spraying. During the deposition process, the standoff distance was varied from 80 to 130 mm with 10 mm increments. Other parameters such as current, voltage, time, carrier gas flow rate and powder feed rate etc. were kept constant. The objective was to study the effects of spraying distance on the microstructure of as-sprayed coatings. The microscopic analyses revealed that the band of spraying distance ranging from 90 to 100 mm was the threshold distance for optimum results, provided that all the other spraying parameters were kept constant. In this range of threshold distance, minimum percentages of porosity and defects were observed. Further, the formation of different phases, at six spraying distances, was studied using X-ray diffraction, and the phase analysis was correlated with hardness results.

  10. Testing of Flame Sprayed Al2O3 Matrix Coatings Containing TiO2

    Directory of Open Access Journals (Sweden)

    Czupryński A.

    2016-09-01

    Full Text Available The paper presents the results of the properties of flame sprayed ceramic coatings using oxide ceramic materials coating of a powdered aluminium oxide (Al2O3 matrix with 3% titanium oxide (TiO2 applied to unalloyed S235JR grade structural steel. A primer consisting of a metallic Ni-Al-Mo based powder has been applied to plates with dimensions of 5×200×300 mm and front surfaces of Ø40×50 mm cylinders. Flame spraying of primer coating was made using a RotoTec 80 torch, and an external coating was made with a CastoDyn DS 8000 torch. Evaluation of the coating properties was conducted using metallographic testing, phase composition research, measurement of microhardness, substrate coating adhesion (acc. to EN 582:1996 standard, erosion wear resistance (acc. to ASTM G76-95 standard, and abrasive wear resistance (acc. to ASTM G65 standard and thermal impact. The testing performed has demonstrated that flame spraying with 97% Al2O3 powder containing 3% TiO2 performed in a range of parameters allows for obtaining high-quality ceramic coatings with thickness up to ca. 500 µm on a steel base. Spray coating possesses a structure consisting mainly of aluminium oxide and a small amount of NiAl10O16 and NiAl32O49 phases. The bonding primer coat sprayed with the Ni-Al-Mo powder to the steel substrate and external coating sprayed with the 97% Al2O3 powder with 3% TiO2 addition demonstrates mechanical bonding characteristics. The coating is characterized by a high adhesion to the base amounting to 6.5 MPa. Average hardness of the external coating is ca. 780 HV. The obtained coatings are characterized by high erosion and abrasive wear resistance and the resistance to effects of cyclic thermal shock.

  11. Effect of flame conditions on abrasive wear performance of HVOF sprayed nanostructured WC-12Co coatings

    Institute of Scientific and Technical Information of China (English)

    WANG Yu-yue; LI Chang-jiu; MA Jian; YANG Guan-jun

    2004-01-01

    Nanostructured WC-12Co coatings were deposited by high velocity oxy-fuel (HVOF) spraying with an agglomerated powder. The effect of flame conditions on the microstructure of the nanostructured coatings was investigated. The wear properties of the coatings were characterized using a dry rubber-wheel wear test. The results show that the nanostructured WC-Co coatings consist of WC, W2C, W and an amorphous binder phase. The microstructure of the coating is significantly influenced by the ratio of oxygen flow to fuel flow. Under the lower ratio of oxygen/fuel flow, the nanostructured coating presents a relative dense microstructure and severe decarburization of WC phase occurs during spraying. With increasing ratio of oxygen/fuel flow, the bonding of WC particles in the coating becomes loose resulting from the original structure of feedstock and the decarburization of WC becomes less owing to limited heating to the powder. Both the decarburization of WC particles in spraying and the bonding among WC particles in the coatings affect the wear performance. The examination of the worn surfaces of the nanostructured coatings reveals that the dominant wear mechanisms would be spalling from the interface of WCCo splats when spray particles undergo a limited melting. While the melting state of the spray particles is improved,the dominant wear mechanisms become the plastic deformation and plowing of the matrix and spalling of WC particles from the matrix.

  12. Abrasion, Erosion and Cavitation Erosion Wear Properties of Thermally Sprayed Alumina Based Coatings

    Directory of Open Access Journals (Sweden)

    Ville Matikainen

    2014-01-01

    Full Text Available Thermally-sprayed alumina based materials, e.g., alumina-titania (Al2O3-TiO2, are commonly applied as wear resistant coatings in industrial applications. Properties of the coatings depend on the spray process, powder morphology, and chemical composition of the powder. In this study, wear resistant coatings from Al2O3 and Al2O3-13TiO2 powders were sprayed with plasma and high-velocity oxygen-fuel (HVOF spray processes. Both, fused and crushed, and agglomerated and sintered Al2O3-13TiO2 powders were studied and compared to pure Al2O3. The coatings were tested for abrasion, erosion, and cavitation resistances in order to study the effect of the coating structure on the wear behavior. Improved coating properties were achieved when agglomerated and sintered nanostructured Al2O3-13TiO2 powder was used in plasma spraying. Coatings with the highest wear resistance in all tests were produced by HVOF spraying from fused and crushed powders.

  13. Microstructure, microhardness and dry friction behavior of cold-sprayed tin bronze coatings

    Science.gov (United States)

    Guo, Xueping; Zhang, Ga; Li, Wen-Ya; Dembinski, Lucas; Gao, Yang; Liao, Hanlin; Coddet, Christian

    2007-12-01

    In this paper, two types of tin bronze coatings (Cu-6 wt.% Sn and Cu-8 wt.% Sn) were prepared by cold spray process. The as-sprayed coatings were subjected to a vacuum heat treatment at 600 °C for 3 h. The coating microstructure, microhardness and tribological performance were characterized. The effects of the tin content and the vacuum heat treatment on the microstructure, microhardness and tribological behavior of the coatings were investigated. It is found that the as-sprayed CuSn6 (As6) and CuSn8 (As8) coatings exhibit practically an identical porosity. Meanwhile, As8 presents a higher microhardness than As6. In addition, the increase of the tin content in the powder feedstock leads to a lower wear rate. After a heat treatment, coating porosities are significantly reduced. However, the coating hardness is significantly decreased and the coating presents a much decreased wear resistance. For the as-sprayed coatings, such factors as ploughing and particle delamination could determine the sliding process. The heat treatment results in a distinct modification of the tribological behavior. For the annealed coatings, the adhesion, between the coating and the counterpart, could play a dominant role in the sliding process.

  14. Wear behavior of gas tunnel type plasma sprayed Zr-based metallic glass composite coatings

    Energy Technology Data Exchange (ETDEWEB)

    Yugeswaran, S., E-mail: yugeswaran@gmail.com [Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka 567-0047 (Japan); Kobayashi, A., E-mail: kobayasi@jwri.osaka-u.ac.jp [Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka 567-0047 (Japan); Suresh, K., E-mail: ksureshphy@gmail.com [Department of Mechanical and Biomedical Engineering, City University of Hong Kong, Tat Chee Avenue, Kowloon, Hong Kong Special Administrative Region (China); Rao, K.P., E-mail: mekprao@cityu.edu.hk [Department of Mechanical and Biomedical Engineering, City University of Hong Kong, Tat Chee Avenue, Kowloon, Hong Kong Special Administrative Region (China); Subramanian, B., E-mail: subramanianb3@gmail.com [CSIR - Central Electrochemical Research Institute, Karaikudi 630 006 (India)

    2012-09-01

    Highlights: Black-Right-Pointing-Pointer Zr-based metallic glass composite coatings are prepared by gas tunnel plasma torch. Black-Right-Pointing-Pointer Increasing plasma current increases crystallinity amount and hardness of coatings. Black-Right-Pointing-Pointer Coating produced at 300 A plasma current gives minimum sliding wear rate. Black-Right-Pointing-Pointer Coating produced at higher plasma current gives lower erosive wear rate. - Abstract: Gas tunnel type plasma spraying is a prospective method to produce metallic glass composite coatings with high quality due to its noteworthy feature of process controllability. In this study, Zr{sub 55}Cu{sub 30}Al{sub 10}Ni{sub 5} metallic glass composite coatings were produced by gas tunnel type plasma spraying torch under optimum spraying conditions with selected plasma currents. The formation mechanism, sliding, and erosive wear behaviors of the coatings with respect to plasma current was examined. The phase and thermal analyses as well as microstructure of the plasma sprayed coatings produced at different plasma currents were characterized using X-ray diffraction (XRD), differential scanning calorimetry (DSC), scanning electron microscopy (SEM), and energy dispersive X-ray spectroscopy (EDX) techniques. The sliding and erosive wear behaviors of the coatings were studied using a pin-on-disc and a specially designed erosive wear tester, respectively. The results showed that an increase in plasma current increased the crystalline content in the metallic glass composite coatings, which enhanced the hardness and wear resistance of the coatings.

  15. Oxidation Control of Atmospheric Plasma Sprayed FeAl Intermetallic Coatings Using Dry-Ice Blasting

    Science.gov (United States)

    Song, Bo; Dong, Shujuan; Coddet, Pierre; Hansz, Bernard; Grosdidier, Thierry; Liao, Hanlin; Coddet, Christian

    2013-03-01

    The performance of atmospheric plasma sprayed FeAl coatings has been remarkably limited because of oxidation and phase transformation during the high-temperature process of preparation. In the present work, FeAl intermetallic coatings were prepared by atmospheric plasma spraying combined with dry-ice blasting. The microstructure, oxidation, porosity, and surface roughness of FeAl intermetallic coatings were investigated. The results show that a denser FeAl coating with a lower content of oxide and lower degree of phase transformation can be achieved because of the cryogenic, the cleaning, and the mechanical effects of dry-ice blasting. The surface roughness value decreased, and the adhesive strength of FeAl coating increased after the application of dry-ice blasting during the atmospheric plasma spraying process. Moreover, the microhardness of the FeAl coating increased by 72%, due to the lower porosity and higher dislocation density.

  16. Characterisation of the TiO2 coatings deposited by plasma spraying

    Science.gov (United States)

    Benea, M. L.; Benea, L. P.

    2016-02-01

    Plasma spraying of materials such as ceramics and non-metals, which have high melting points, has become a well-established commercial process. Such coatings are increasingly used in aerospace, automobile, textile, medical, printing and electrical industries to impart proprieties such as corrosion resistance, thermal resistance, wear resistance, etc. One of the most important characteristics of thermal barrier coatings is the ability to undergo fast temperature changes without failing, the so called thermal shock resistance. The formation of residual stresses in plasma sprayed ceramic and metallic coatings is a very complex process. Several factors, such as substrate material, substrate thickness, physical properties of both the substrate and the coating material, deposition rate, relative velocity of the plasma torch, etc. determine the final residual stress state of the coating at room temperature. Our objective is to characterize the titanium oxide and aluminium oxide coatings deposited by plasma spraying in structural terms, the resistance to thermal shock and residual stresses.

  17. The influence of mechanical vibrations on microstructure of Ni-based thermally sprayed-fused coatings

    Directory of Open Access Journals (Sweden)

    Jelena ŠKAMAT

    2013-12-01

    Full Text Available The influence of mechanical vibrations on microstructure and properties of Ni-based thermally sprayed and fused coatings deposited on a steel substrate has been studied. Self-fluxing powder with about 73% Ni was used as a sprayed material. As-sprayed coatings were refused using conventional flame technique and with introducing of mechanical vibrations. In result coatings with quite complicated microstructure were obtained. During investigation of coatings by different methods it was found that vibratory treatment really influences the solidified microstructure. It was found that vibrations promote densimetric movement of hard particles up - towards a surface with forming of thicker so-called “hard-inclusions-free” layer near interface. Some tendency was noted that coatings, remelted under vibrations, showed better corrosion and high-temperature oxidation resistance in comparison with coatings created without vibrational treatment during solidification.

  18. Characterization of NiCrAlC PTA coatings

    OpenAIRE

    2012-01-01

    Surface tailoring with plasma transferred arc (PTA) hardfacing involves the deposition of powder mixtures to produce coatings with an almost unlimited chemical composition. PTA hardfacing is particularly important for processing low weldability alloys, such as those for high-temperature applications, of which NiCrAlC is an example. This study analyzed NiCrAlC coatings processed by PTA using a mixture of elemental powders. Deposition on AISI316L plates was carried out with currents of 100 A an...

  19. Granulometric characterization of airborne particulate release during spray application of nanoparticle-doped coatings

    Science.gov (United States)

    Göhler, Daniel; Stintz, Michael

    2014-08-01

    Airborne particle release during the spray application of coatings was analyzed in the nanometre and micrometre size range. In order to represent realistic conditions of domestic and handcraft use, the spray application was performed using two types of commercial propellant spray cans and a manual gravity spray gun. Four different types of coatings doped with three kinds of metal-oxide tracer nanoparticle additives (TNPA) were analyzed. Depending on the used coating and the kind of spray unit, particulate release numbers between 5 × 108 and 3 × 1010 particles per gram ejection mass were determined in the dried spray aerosols. The nanoparticulate fraction amounted values between 10 and 60 no%. The comparison between nanoparticle-doped coatings with non-doped ones showed no TNPA-attributed differences in both the macroscopic spray process characteristics and the particle release numbers. SEM, TEM and EDX-analyzes showed that the spray aerosols were composed of particles made up solely from matrix material and sheathed pigments, fillers and TNPAs. Isolated ZnO- or Fe2O3-TNPAs could not be observed.

  20. Granulometric characterization of airborne particulate release during spray application of nanoparticle-doped coatings.

    Science.gov (United States)

    Göhler, Daniel; Stintz, Michael

    2014-01-01

    Airborne particle release during the spray application of coatings was analyzed in the nanometre and micrometre size range. In order to represent realistic conditions of domestic and handcraft use, the spray application was performed using two types of commercial propellant spray cans and a manual gravity spray gun. Four different types of coatings doped with three kinds of metal-oxide tracer nanoparticle additives (TNPA) were analyzed. Depending on the used coating and the kind of spray unit, particulate release numbers between 5 × 10(8) and 3 × 10(10) particles per gram ejection mass were determined in the dried spray aerosols. The nanoparticulate fraction amounted values between 10 and 60 no%. The comparison between nanoparticle-doped coatings with non-doped ones showed no TNPA-attributed differences in both the macroscopic spray process characteristics and the particle release numbers. SEM, TEM and EDX-analyzes showed that the spray aerosols were composed of particles made up solely from matrix material and sheathed pigments, fillers and TNPAs. Isolated ZnO- or Fe2O3-TNPAs could not be observed.

  1. CREATION OF GRADIENT PLASMA-SPRAYED COATINGS ON BASIS OF ZIRCONIUM DIOXIDE STABILIZED WITH YTTERBIUM DIOXIDE

    Directory of Open Access Journals (Sweden)

    V. A. Okovity

    2011-01-01

    Full Text Available The process has been investigated and technological parameters for spraying gradient plasma coatings on the basis of zirconium dioxide stabilized with ytterbium dioxide have been optimized in the paper.

  2. Spray-coating of superhydrophobic aluminum alloys with enhanced mechanical robustness.

    Science.gov (United States)

    Zhang, Youfa; Ge, Dengteng; Yang, Shu

    2014-06-01

    A superhydrophobic aluminum alloy was prepared by one-step spray coating of an alcohol solution consisting of hydrophobic silica nanoparticles (15-40 nm) and methyl silicate precursor on etched aluminum alloy with pitted morphology. The as-sprayed metal surface showed a water contact angle of 155° and a roll-off angle of 4°. The coating was subjected to repeated mechanical tests, including high-pressure water jetting, sand particles impacting, and sandpaper shear abrasion. It remained superhydrophobic with a roll-off angle coating mechanical robustness, where the nanoparticles could grab on the rough surface, specifically in the groove structures, in comparison with the smooth glass substrates spray coated with the same materials. Further, we showed that the superhydrophobicity could be restored by spray a new cycle of the nanocomposite solution on the damaged surface. Copyright © 2014 Elsevier Inc. All rights reserved.

  3. Spray-coating process in preparing PTFE-PPS composite super-hydrophobic coating

    Directory of Open Access Journals (Sweden)

    Rui Weng

    2014-03-01

    Full Text Available In order to improve the performance of a liquid-floated rotor micro-gyroscope, the resistance of the moving interface between the rotor and the floating liquid must be reduced. Hydrophobic treatment can reduce the frictional resistance between such interfaces, therefore we proposed a method to prepare a poly-tetrafluoroethylene (PTFE-poly-phenylene sulphide (PPS composite super-hydrophobic coating, based on a spraying process. This method can quickly prepare a continuous, uniform PTFE-PPS composite super-hydrophobic surface on a 2J85 material. This method can be divided into three steps, namely: pre-treatment; chemical etching; and spraying. The total time for this is around three hours. When the PTFE concentration is 4%, the average contact angle of the hydrophobic coating surface is 158°. If silicon dioxide nanoparticles are added, this can further improve the adhesion and mechanical strength of the super-hydrophobic composite coating. The maximum average contact angle can reach as high as 164° when the mass fraction of PTFE, PPS and silicon dioxide is 1:1:1.

  4. Cold spray deposition of Ti2AlC coatings for improved nuclear fuel cladding

    Science.gov (United States)

    Maier, Benjamin R.; Garcia-Diaz, Brenda L.; Hauch, Benjamin; Olson, Luke C.; Sindelar, Robert L.; Sridharan, Kumar

    2015-11-01

    Coatings of Ti2AlC MAX phase compound have been successfully deposited on Zircaloy-4 (Zry-4) test flats, with the goal of enhancing the accident tolerance of LWR fuel cladding. Low temperature powder spray process, also known as cold spray, has been used to deposit coatings ∼90 μm in thickness using powder particles of accident tolerance to nuclear fuel cladding.

  5. Experimental modeling of polymer latex spray coating for producing controlled-release urea

    Institute of Scientific and Technical Information of China (English)

    Rui Lan; Yonghui Liu; Guanda Wang; Tingjie Wang; Chengyou Kan; Yong Jin

    2011-01-01

    Spray coating of polymer latex onto fertilizer particles in a fluidized bed for producing controlled-release urea is an environment friendly technology as it does not need any toxic organic solvent.Since the spray coating process in a fluidized bed occurs in the presence of particle collisions,the coating of the particles is random,intermittent and multiple,thus making it difficult to investigate the film formation process.In this paper,an experimental model apparatus was designed and used to investigate the effects of the key factors in the spray coating process.This apparatus reasonably simplified the complex process to avoid particle collisions and randomness in the coating.The intermittent coating in the fluidized bed was modeled by periodic coating and dewatering in the experimental apparatus.A large area film was obtained,and the film permeability was measured.The effects of atomizing gas flow rate,spray rate of latex,solid content of latex and gas temperature on film structure and film permeability were investigated.It was found that water transfer played a dominant role in the spray coating process.

  6. Sealing of thermally-sprayed stainless steel coatings against corrosion using nickel electroplating technique

    Directory of Open Access Journals (Sweden)

    Hathaipat Koiprasert

    2007-07-01

    Full Text Available Electric arc spraying (EAS is one of the thermal spray techniques used for restoration and to providecorrosion resistance. It can be utilized to build up coatings to thicknesses of several millimeters, It is easy to use on-site. Most importantly, the cost of this technique is lower than other thermal spraying techniques thatmay be suitable for part restoration. A major disadvantage associated with the electric arc sprayed coating is its high porosity, which can be as high as 3-8% making it not appropriate for use in immersion condition. This work was carried out around the idea of using electroplating to seal off the pore of the EAS coating, with an aim to improve the corrosion resistance of the coating in immersion condition. This research compared the corrosion behavior of a stainless steel 316 electric arc sprayed coating in 2M NaOH solution at 25oC. It was found that the Ni plating used as sealant can improve the corrosion resistance of the EAS coating. Furthermore, the smoothened and plated stainless steel 316 coating has a better corrosion resistance than the plated EAS coating that was not ground to smoothen the surface before plating.

  7. In vitro fatigue behaviour of vacuum plasma and detonation gun sprayed hydroxyapatite coatings.

    Science.gov (United States)

    Gledhill, H C; Turner, I G; Doyle, C

    2001-06-01

    The fatigue behaviour of vacuum plasma sprayed (VPS) and detonation gun sprayed (DGUN) hydroxyapatite coatings on titanium substrates has been compared in air and in buffered Ringer's solution. There was an increase in the surface microcracking and bulk porosity of both types of coating tested in air. After 1 million cycles in Ringer's solution the VPS coatings had completely delaminated from their substrates. In contrast the DGUN coatings retained their integrity when tested up to 10 million cycles but were beginning to show signs of delamination at the interface.

  8. Nanostructured Thermal Spray Feedstocks:the Next Generation of Engineered Coatings

    Institute of Scientific and Technical Information of China (English)

    T.Danny Xiao

    2000-01-01

    This paper presents an overview of the recent research activities at lnframat(R)Corporation(IMC)on the development of thermal spray processes for nanostructured coatings, which enable improved performance and durability of coated components. Designed multifunctional nanocoatings present unprecedented opportunities for advances in materials properties and performance for a broad range of engineered surface applications.The technology described in this paper involves the reconstitution of individual nanoparticles into sprayable micron-sized agglomerates, followed by the thermal spray of these agglomerated granules into a high performance nanostructured coating.One important feature of the nanostructured coatings is their improved toughness,contributing to a significant improvement in wear resistance.

  9. Preparation and Properties of Plasma Spraying Cu-Al2O3 Gradient Coatings

    Institute of Scientific and Technical Information of China (English)

    Ali LEI; Nan DONG; Lajun FENG

    2007-01-01

    In order to overcome the limitations of low adhesion strength and poor thermal-shock resistance of pure ceramic coatings, Cu-Al2O3 gradient coatings were fabricated by plasma spraying. The microstructure and distribution of Cu-Al2O3 gradient coatings were analyzed. The adhesion strength, thermal-shock resistance and porosity of the coatings were tested. The results show that the composition of the gradient coatings has a gradient distribution along the thickness of coatings. As copper has a relatively low melting point and the molten copper has good wettability on the surface of Al2O3, it can be melted sufficiently and could fill the interstices and pores among the spraying particles effectively, thus improves the adhesion strength, thermal shock resistance and reduces the porosity. The adhesion strength of the gradient coating is 15.2 MPa which is two times of that of the double-layer structure coating.

  10. Preparation and characterization of molybdenum disilicide coating on molybdenum substrate by air plasma spraying

    Energy Technology Data Exchange (ETDEWEB)

    Wang, Yi [Key Laboratory of Ministry of Education for Non-ferrous Materials Science and Engineering, Central South University, Changsha 410083 (China); Key Laboratory of Hunan Province for Metallurgy and Material Processing of Rare Metals, Central South University, Changsha 410083 (China); School of Materials Science and Engineering, Central South University, Changsha 410083 (China); Wang, Dezhi, E-mail: dzwang68@163.com [Key Laboratory of Ministry of Education for Non-ferrous Materials Science and Engineering, Central South University, Changsha 410083 (China); Key Laboratory of Hunan Province for Metallurgy and Material Processing of Rare Metals, Central South University, Changsha 410083 (China); School of Materials Science and Engineering, Central South University, Changsha 410083 (China); Yan, Jianhui [Advanced Materials Synthesis and Application Technology Laboratory, Hunan University of Science and Technology, Xiangtan 411201 (China); Sun, Aokui [Key Laboratory of Ministry of Education for Non-ferrous Materials Science and Engineering, Central South University, Changsha 410083 (China); Key Laboratory of Hunan Province for Metallurgy and Material Processing of Rare Metals, Central South University, Changsha 410083 (China); School of Materials Science and Engineering, Central South University, Changsha 410083 (China)

    2013-11-01

    MoSi{sub 2} oxidation protective coatings on molybdenum substrate were prepared by air plasma spraying technique (APS). Microstructure, phase composition, porosity, microhardness and bonding strength of the coatings were investigated and determined. Oxidation behavior of the coating at high temperature was also examined. Results show that composition of the coatings is constituted with MoSi{sub 2} and Mo{sub 5}Si{sub 3}, the surface morphology is described as flattened lamellar features, insufficiently flattened protuberance with some degree of surface roughness, a certain quantity of spherical particles, microcracks and pores. Testing results reveal that microhardness and bonding strength of the coatings increase, and porosity decreases with increasing power or decreasing Ar gas flow rate. Moreover, with decreasing the porosity, the microhardness of the coatings increases. The bonding strength of the coatings also increases with increasing spray distance. The MoSi{sub 2} coated Mo substrate exhibited a good oxidation resistance at 1200 °C.

  11. High temperature corrosion behavior of arc-sprayed aluminum coatings on steel

    Institute of Scientific and Technical Information of China (English)

    SUN Jian-bo; WANG Yong; DONG Li-xian

    2004-01-01

    Aluminum coatings were sprayed on the substrate of steel Q235 by arc spraying. The test samples of Q235, Al coatings and Al coatings with seal coat were placed in box type electric resistance furnace at 400, 500,600, 650 ℃ when their oxidation behaviors were studied. And their oxidation kinetics curves were protracted. Microstructure, microhardness, bond strength and distribution of section elements were investigated by optical microscope(OM), Vickers microhardness instrument, electric tensile test machine and EPMA. Al coatings and Al coatings with seal coat can enhance the oxidation-resistance of substrate under 500 ℃. The latter has the best corrosion resistance. The coatings can't protect the substrate against oxidation above 600 ℃. After a long time corrosion there is enriched oxygen element at interface.

  12. Fracture Behavior of Cold Sprayed 304 Stainless Steel Coating During Cold Rolling

    Institute of Scientific and Technical Information of China (English)

    MENG Xian-ming; ZHANG Jun-bao; HAN Wei; ZHAO Jie

    2012-01-01

    The fracture behavior of cold sprayed 304 stainless steel coating in cold rolling process was studied. The 304 stainless steel coatings were deposited on low carbon steel substrate by cold gas dynamic spray (CGDS) and then cold rolled, respectively. The fracture morphology of the coatings was observed and analyzed, and the crack distri- butions along the longitudinal rolling direction of the coatings were also investigated and discussed. The results showed that the cohesive strength of the cold sprayed 304 stainless steel coating was too low to be cold rolled. Mi crocracks were formed in the as-sprayed coatings and ran perpendicularly to the rolling direction. The spacing dis- tance between these cracks decreased with the increase of the cold rolling reduction. In addition, it was also found that the initial crack generated at the surface of the coating and propagated from the surface to the interface along the weakly bonded particles. A theoretical analysis was developed for the coating fracture. It gave a critical minimum cohesive bonding strength of the coating for non-breaking in cold rolling process. The crack propagation manner of the cold rolled coatings was also discussed.

  13. Studies on Nanocrystalline TiN Coatings Prepared by Reactive Plasma Spraying

    Directory of Open Access Journals (Sweden)

    Dong Yanchun

    2008-01-01

    Full Text Available Titanium nitride (TiN coatings with nanostructure were prepared on the surface of 45 steel (Fe-0.45%C via reactive plasma spraying (denoted as RPS Ti powders using spraying gun with self-made reactive chamber. The microstructural characterization, phases constitute, grain size, microhardness, and wear resistance of TiN coatings were systematically investigated. The grain size was obtained through calculation using the Scherrer formula and observed by TEM. The results of X-ray diffraction and electron diffraction indicated that the TiN is main phase of the TiN coating. The forming mechanism of the nano-TiN was characterized by analyzing the SEM morphologies of surface of TiN coating and TiN drops sprayed on the surface of glass, and observing the temperature and velocity of plasma jet using Spray Watch. The tribological properties of the coating under nonlubricated condition were tested and compared with those of the AISI M2 high-speed steel and Al2O3 coating. The results have shown that the RPS TiN coating presents better wear resistance than the M2 high-speed steel and Al2O3 coating under nonlubricated condition. The microhardness of the cross-section and longitudinal section of the TiN coating was tested. The highest hardness of the cross-section of TiN coating is 1735.43HV100 g.

  14. Performance Testing of Suspension Plasma Sprayed Thermal Barrier Coatings Produced with Varied Suspension Parameters

    Directory of Open Access Journals (Sweden)

    Nicholas Curry

    2015-07-01

    Full Text Available Suspension plasma spraying has become an emerging technology for the production of thermal barrier coatings for the gas turbine industry. Presently, though commercial systems for coating production are available, coatings remain in the development stage. Suitable suspension parameters for coating production remain an outstanding question and the influence of suspension properties on the final coatings is not well known. For this study, a number of suspensions were produced with varied solid loadings, powder size distributions and solvents. Suspensions were sprayed onto superalloy substrates coated with high velocity air fuel (HVAF -sprayed bond coats. Plasma spray parameters were selected to generate columnar structures based on previous experiments and were maintained at constant to discover the influence of the suspension behavior on coating microstructures. Testing of the produced thermal barrier coating (TBC systems has included thermal cyclic fatigue testing and thermal conductivity analysis. Pore size distribution has been characterized by mercury infiltration porosimetry. Results show a strong influence of suspension viscosity and surface tension on the microstructure of the produced coatings.

  15. Preparation of SrZrO3 Thermal Barrier Coating by Solution Precursor Plasma Spray

    Science.gov (United States)

    Li, Xinhui; Ma, Wen; Wen, Jing; Bai, Yu; Sun, Li; Chen, Baodong; Dong, Hongying; Shuang, Yingchai

    2017-02-01

    The solution precursor plasma spray (SPPS) process is capable of depositing highly durable thermal barrier coatings (TBCs). In this study, an aqueous chemical precursor feedstock was injected into the plasma jet to deposit SrZrO3 thermal barrier coating on metal substrate. Taguchi design of experiments was employed to optimize the SPPS process. The thermal characteristics and phase evolution of the SrZrO3 precursor, as well as the influence of various spray parameters on the coating deposition rate, microhardness, microstructure, and phase stability, were investigated. The experimental results showed that, at given spray distance, feedstock flow rate, and atomization pressure, the optimized spray parameters were arc current of 600 A, argon flow rate of 40 L/min, and hydrogen flow rate of 10 L/min. The SrZrO3 coating prepared using the optimized spray parameters had single-pass thickness of 6.0 μm, porosity of 18%, and microhardness of 6.8 ± 0.1 GPa. Phase stability studies indicated that the as-sprayed SrZrO3 coating had good phase stability in the temperature range from room temperature to 1400 °C, gradually exhibiting a phase transition from t'-ZrO2 to m-ZrO2 in the SrZrO3 coating at 1450 °C with increasing time, while the SrZrO3 phase did not change.

  16. Effect of substrate preheating temperature and coating thickness on residual stress in plasma sprayed hydroxyapatite coating

    Science.gov (United States)

    Tang, Dapei

    2015-07-01

    A thermal-mechanical coupling model was developed based on thermal-elastic- plastic theory according the special process of plasma spraying Hydroxyapatite (HA) coating upon Ti-6Al-4V substrate. On the one hand, the classical Fourier transient heat conduction equation was modified by introducing the effect item of deformation on temperature, on the other hand, the Johnson-Cook model, suitable for high temperature and high strain rate conditions, was used as constitutive equation after considering temperature softening effect, strain hardening effect and strain rate reinforcement effect. Based on the above coupling model, the residual stress field within the HA coating was simulated by using finite element method (FEM). Meanwhile, the substrate preheating temperature and coating thickness on the influence of residual stress components were calculated, respectively. The failure modes of coating were also preliminary analyzed. In addition, in order to verify the reliability of calculation, the material removal measurement technique was applied to determine the residual stress of HA coating near the interface. Some important conclusions are obtained.

  17. Stress gradients in CrN coatings

    NARCIS (Netherlands)

    Janssen, G.C.A.M.; Tichelaar, F.D.; Visser, C.C.G.

    2006-01-01

    Stress in hard films is the net sum of tensile stress generated at the grain boundaries, compressive stress due to ion peening, and thermal stress due to the difference in thermal expansion of the coating and substrate. The tensile part due to grain boundaries is thickness dependent. The other two c

  18. Optimization Of Multi-Module CrN/CrCN Coatings

    Directory of Open Access Journals (Sweden)

    Szparaga Ł.

    2015-06-01

    Full Text Available In the paper was proposed optimization procedure supporting the prototyping of the geometry of multi-module CrN/CrCN coatings, deposited on substrates from 42CrMo4 steel, in respect of mechanical properties. Adopted decision criteria were the functions of the state of internal stress and strain in the coating and substrate, caused by external mechanical loads. Using developed optimization procedure the set of optimal solutions (Pareto-optimal solutions of coatings geometry parameters, due to the adopted decision criteria was obtained. For the purposes of analysis of obtained Pareto-optimal solutions, their mutual distance in the space of criteria and decision variables were calculated, which allowed to group solutions in the classes. Also analyzed the number of direct neighbors of Pareto-optimal solutions for the purposes of assessing the stability of solutions.

  19. One-step spray-coating process for the fabrication of colorful superhydrophobic coatings with excellent corrosion resistance.

    Science.gov (United States)

    Li, Jian; Wu, Runni; Jing, Zhijiao; Yan, Long; Zha, Fei; Lei, Ziqiang

    2015-10-06

    A simple method was used to generate colorful hydrophobic stearate particles via chemical reactions between inorganic salts and sodium stearate. Colored self-cleaning superhydrophobic coatings were prepared through a facile one-step spray-coating process by spraying the stearate particle suspensions onto stainless steel substrates. Furthermore, the colorful superhydrophobic coating maintains excellent chemical stability under both harsh acidic and alkaline circumstances. After being immersed in a 3.5 wt % NaCl aqueous solution for 1 month, the as-prepared coatings remained superhydrophobic; however, they lost their self-cleaning property with a sliding angle of about 46 ± 3°. The corrosion behavior of the superhydrophobic coatings on the Al substrate was characterized by the polarization curve and electrochemical impedance spectroscopy (EIS). The electrochemical corrosion test results indicated that the superhydrophobic coatings possessed excellent corrosion resistance, which could supply efficient and long-term preservation for the bare Al substrate.

  20. Nondestructive Evaluation of Thermal Spray Coating Interface Quality by Eddy Current Method

    Science.gov (United States)

    Mi, Bao; Zhao, Xiaoliang (George); Bayles, Robert

    2007-03-01

    Thermal spray coating is usually applied through directing molten or softened particles at very high velocities onto a substrate. An eddy current non-destructive inspection technique is presented here for thermal spray coating interface quality characterization. Several high-velocity-oxy-fuel (HVOF) coated steel plates were produced with various surface preparation conditions or spray process parameters. A quad-frequency eddy current probe was used to manually scan over the coating surface to evaluate the bonding quality. Experimental results show that different surface preparation conditions and varied process parameters can be successfully differentiated by the impedance value observed from the eddy current probe. The measurement is fairly robust and consistent. This non-contact, nondestructive, easy-to-use technique has the potential for evaluating the coating quality immediately after its application so that any defects can be corrected immediately.

  1. Determination of elastic modulus and residual stress of plasma-sprayed tungsten coating on steel substrate

    Energy Technology Data Exchange (ETDEWEB)

    You, J.H. [Max-Planck-Institut fuer Plasmaphysik, EURATOM Association, Boltzmann Street 2, 85748 Garching (Germany)]. E-mail: jeong-ha.you@ipp.mpg.de; Hoeschen, T. [Max-Planck-Institut fuer Plasmaphysik, EURATOM Association, Boltzmann Street 2, 85748 Garching (Germany); Lindig, S. [Max-Planck-Institut fuer Plasmaphysik, EURATOM Association, Boltzmann Street 2, 85748 Garching (Germany)

    2006-01-01

    Plasma-sprayed tungsten, which is a candidate material for the first wall armour, shows a porous, heterogeneous microstructure. Due to its characteristic morphology, the properties are significantly different from those of its dense bulk material. Measurements of the elastic modulus of this coating have not been reported in the literature. In this work Young's modulus of highly porous plasma-sprayed tungsten coatings deposited on steel (F82H) substrates was measured. For the fabrication of the coating system the vacuum plasma-spray process was applied. Measurements were performed by means of three-point and four-point bending tests. The obtained modulus values ranged from 53 to 57 GPa. These values could be confirmed by the test result of a detached coating strip, which was 54 GPa. The applied methods produced consistent results regardless of testing configurations and specimen sizes. The errors were less than 1%. Residual stress of the coating was also estimated.

  2. Determination of elastic modulus and residual stress of plasma-sprayed tungsten coating on steel substrate

    Science.gov (United States)

    You, J. H.; Höschen, T.; Lindig, S.

    2006-01-01

    Plasma-sprayed tungsten, which is a candidate material for the first wall armour, shows a porous, heterogeneous microstructure. Due to its characteristic morphology, the properties are significantly different from those of its dense bulk material. Measurements of the elastic modulus of this coating have not been reported in the literature. In this work Young's modulus of highly porous plasma-sprayed tungsten coatings deposited on steel (F82H) substrates was measured. For the fabrication of the coating system the vacuum plasma-spray process was applied. Measurements were performed by means of three-point and four-point bending tests. The obtained modulus values ranged from 53 to 57 GPa. These values could be confirmed by the test result of a detached coating strip, which was 54 GPa. The applied methods produced consistent results regardless of testing configurations and specimen sizes. The errors were less than 1%. Residual stress of the coating was also estimated.

  3. Mechanical, In Vitro Antimicrobial and Biological Properties of Plasma Sprayed Silver-Doped Hydroxyapatite Coating

    OpenAIRE

    Roy, Mangal; Fielding, Gary A.; BEYENAL, Haluk; Bandyopadhyay, Amit; Bose, Susmita

    2012-01-01

    Implant related infection is one of the key concerns in total joint hip arthroplasties. In order to reduce bacterial adhesion, silver (Ag) / silver oxide (Ag2O) doping was used in plasma sprayed hydroxyapatite (HA) coating on titanium substrate. HA powder was doped with 2.0, 4.0 and 6.0 wt% Ag, heat treated at 800 °C and used for plasma spray coating using a 30 kW plasma spray system, equipped with supersonic nozzle. Application of supersonic plasma nozzle significantly reduced phase decompos...

  4. Residual stress in sprayed Ni+5%Al coatings determined by neutron diffraction

    CERN Document Server

    Matejicek, J; Gnaeupel-Herold, T; Prask, H J

    2002-01-01

    Coatings of nickel-based alloys are used in numerous high-performance applications. Their properties and lifetimes are influenced by factors such as residual stress. Neutron diffraction is a powerful tool for nondestructive residual stress determination. In this study, through-thickness residual stress profiles in Ni+5%Al coatings on steel substrates were determined. Two examples of significantly different spraying techniques - plasma spraying and cold spraying - are highlighted. Different stress-generation mechanisms are discussed with respect to process parameters and material properties. (orig.)

  5. Spray-coated nanoscale conductive patterns based on in situ sintered silver nanoparticle inks

    Science.gov (United States)

    2014-01-01

    Nanoscale patterns with high conductivity based on silver nanoparticle inks were fabricated using spray coating method. Through optimizing the solution content and spray operation, accurate nanoscale patterns consisting of silver nanoparticles with a square resistance lower than 1 Ω /cm2 were obtained. By incorporating in situ sintering to substitute the general post sintering process, the time consumption could be significantly reduced to one sixth, qualifying it for large-scale and cost-effective fabrication of printed electronics. To testify the application of spray-coated silver nanoparticle inks, an inverted polymer solar cell was also fabricated, which exhibited a power conversion efficiency of 2.76%. PMID:24666992

  6. Comparative of the Tribological Performance of Hydraulic Cylinders Coated by the Process of Thermal Spray HVOF and Hard Chrome Plating

    Directory of Open Access Journals (Sweden)

    R.M. Castro

    2014-03-01

    Full Text Available Due to the necessity of obtaining a surface that is resistant to wear and oxidation, hydraulic cylinders are typically coated with hard chrome through the process of electroplating process. However, this type of coating shows an increase of the area to support sealing elements, which interferes directly in the lubrication of the rod, causing damage to the seal components and bringing oil leakage. Another disadvantage in using the electroplated hard chromium process is the presence of high level hexavalent chromium Cr+6 which is not only carcinogenic, but also extremely contaminating to the environment. Currently, the alternative process of high-speed thermal spraying (HVOF - High Velocity Oxy-Fuel, uses composite materials (metal-ceramic possessing low wear rates. Research has shown that some mechanical properties are changed positively with the thermal spray process in industrial applications. It is evident that a coating based on WC has upper characteristics as: wear resistance, low friction coefficient, with respect to hard chrome coatings. These characteristics were analyzed by optical microscopy, roughness measurements and wear test.

  7. Study for prevention of sucker rods failures though NiCr coating; Estudo para prevencao de falhas de hastes de bombeio de petroleo atraves de aplicacao de revestimento NiCr

    Energy Technology Data Exchange (ETDEWEB)

    Bezerra, Brunno S.L. [PETROBRAS, Rio de Janeiro, RJ (Brazil); Araujo, Paulo M.M. [Universidade Federal de Sergipe (UFS), Aracaju, SE (Brazil); Figueiredo, Renan T.; Cavalcanti, Eliane B. [Universidade Tiradentes, Aracaju, SE (Brazil)

    2008-07-01

    The use of common materials, as carbon steel, in sucker rods motivated by its low cost, in mature oil wells located on Sergipe, Alagoas, Bahia and Rio Grande do Norte states, which are subjected to tractive-compressive-abrasive like combined loads, added to aggressive environment (oil production in the presence of water, carbon dioxide, hydrogen sulfide, salinity, etc..), leads to the materials drastic degeneration and even its rupture. The substitution of common materials by those which have better resistance o failure is, therefore, limited by high cost. A much cheaper alternative is to modify the surface of common materials used in the subsurface equipment, by applying a protective coating in order to assure the system's performance, durability or better economic viability. In the present work it was studied the use of thermal sprayed NiCr coating in sucker rods. It was studied three thermal spray processes: flame spray, arc spray and HVOF (high velocity oxy fuel). (author)

  8. A Study on the Cyclic Oxidation Behavior of Detonation-Gun-Sprayed Ni-5Al Coatings on Inconel-718 at 900 °C

    Science.gov (United States)

    Saladi, Sekar; Menghani, Jyoti; Prakash, Satya

    2014-12-01

    Cyclic oxidation behavior of detonation-gun-sprayed Ni-5Al coating on Inconel-718 is discussed in the present study. Oxidation studies were carried out on both bare and coated superalloy substrates in air at 900 °C for 100 cycles. The thermogravimetric technique was used to establish kinetics of oxidation. X-ray diffraction, FESEM/EDAX, and x-ray mapping techniques were used to analyze the oxidation products of bare and coated samples. The weight gain of bare superalloy was higher than the Ni-5Al-coated superalloy. Both bare and Ni-5Al-coated superalloys followed nearly parabolic oxidation behavior. The Ni-5Al coating was able to reduce the overall weight gain by 26.2% in comparison with bare superalloy in the given environment. The better oxidation resistance of Ni-5Al coating may be due the formation of protective oxides phases such as NiO, Al2O3, and NiAl2O4 on the oxidized coating and Cr2O3 at the coating-substrate interface. The Ni-5Al coatings obtained from detonation-gun-spraying process showed very little porosity and low surface roughness values.

  9. A study on reactive braze coating of (TiC + Cr3 C2 )/Fe composite coatings

    Institute of Scientific and Technical Information of China (English)

    Pei Xinjun; Zhang Jiangang; Zhang Luming; Huang Jihua; Wei Shizhong

    2005-01-01

    A new hardfacing process, reactive braze coating process (RBCC) was studied, and ( TiC + Cr3 C2 ) /Fe composite coatings were prepared by RBCC using carbon, Cr3 C2, iron, ferrochromium and titanium powder as the raw materials in vacuum braze furnace. The results show that TiC is in-situ synthesized in the coatings. The methods of introducing Cr3 C2 have great effects on the distribution of TiC. Adding Cr3 C2 directly to the raw materials for coatings, fine TiC particles aggregate into discoids parallel to the coating surface, whereas, in-situ synthesizing Cr3 C2 in coatings, the aggregations of TiC are lumpish. During braze coating, Cr3 C2 particles directly added dissolve and precipitate to become needle-shaped. The coatings have an even and smooth surface and are combined with their mild steel substrates by a metallurgical bonding.

  10. Apatite formation on alkaline-treated dense TiO2 coatings deposited using the solution precursor plasma spray process.

    Science.gov (United States)

    Chen, Dianying; Jordan, Eric H; Gell, Maurice; Wei, Mei

    2008-05-01

    A dense titania (TiO2) coating was deposited from an ethanol-based solution containing titanium isopropoxide using the solution precursor plasma spray (SPPS) process. XRD and Raman spectrum analyses confirmed that the coating is exclusively composed of rutile TiO2. SEM micrographs show the as-sprayed coating is dense with a uniform thickness and there are no coarse splat boundaries. The as-sprayed coating was chemically treated in 5M NaOH solution at 80 degrees C for 48 h. The bioactivity of as-sprayed and alkaline-treated coatings was investigated by immersing the coatings in simulated body fluid (SBF) for 14-28 days, respectively. After 28 days immersion, there is a complete layer of carbonate-containing apatite formed on the alkaline-treated TiO2 coating surface, but none formed on the as-sprayed coating.

  11. Spray-coating for biopharmaceutical powder formulations: beyond the conventional scale and its application.

    Science.gov (United States)

    Maa, Yuh-Fun; Ameri, Mahmoud; Rigney, Robert; Payne, Lendon G; Chen, Dexiang

    2004-03-01

    Fluid-bed spray-coating process is widely used to prepare non-protein pharmaceutical solid dosage forms using macro-size seed particles (200-1000 microm) at kilogram batch sizes. In this study we developed a small-scale fluid-bed spray-coating process (20 g) to produce micro-sized vaccine powder formulations (40-60 microm) for epidermal powder immunization (EPI) METHODS: A bench-top spray coater was used to spray two vaccines, diphtheria toxoid (dT) and alum-adsorbed hepatitis-B surface antigen (Alum-HBsAg), onto crystalline lactose particles of 40-60 microm in diameter. Particle properties such as particle size, surface morphology, and degree of particle agglomeration were determined. Protein stability was analyzed by sodium dodecyl sulfate-polyacrylamide gel electrophoresis. The immunogenicity of the vaccine was evaluated in vivo by needle injection and epidermal powder immunization (EPI) of mice or guinea pigs. Coating feasibility was demonstrated for both vaccine formulations containing different excipients. However, the nature of the vaccine antigen appeared to affect coating feasibility in terms of particle agglomeration considerably. Delivery of spray-coated dT and alum-HBsAg through EPI to mice and guinea pigs, respectively, generated significant antibody responses, at a level comparable to liquid formulation delivered subcutaneously through needle/syringe injection. The new spray-coating process represents an important technical advance and may provide a useful tool for developing high-valued biopharmaceutical powder formulations for novel applications. The strong in vivo performance of the coated dT and alum-HBsAg powders by EPI further demonstrated that spray-coating is a viable dry powder formulation process and the skin's epidermal layer presents an efficient vaccine delivery route.

  12. Note: Automatic layer-by-layer spraying system for functional thin film coatings

    Science.gov (United States)

    Seo, Seongmin; Lee, Sangmin; Park, Yong Tae

    2016-03-01

    In this study, we have constructed an automatic spray machine for producing polyelectrolyte multilayer films containing various functional materials on wide substrates via the layer-by-layer (LbL) assembly technique. The proposed machine exhibits advantages in terms of automation, process speed, and versatility. Furthermore, it has several features that allow a fully automated spraying operation, such as various two-dimensional spraying paths, control of the flow rate and operating speed, air-assist fan-shaped twin-fluid nozzles, and an optical display. The robot uniformly sprays aqueous mixtures containing complementary (e.g., oppositely charged, capable of hydrogen bonding, or capable of covalent bonding) species onto a large-area substrate. Between each deposition of opposite species, samples are spray-rinsed with deionized water and blow-dried with air. The spraying, rinsing, and drying areas and times are adjustable by a computer program. Twenty-bilayer flame-retardant thin films were prepared in order to compare the performance of the spray-assisted LbL assembly with a sample produced by conventional dipping. The spray-coated film exhibited a reduction of afterglow time in vertical flame tests, indicating that the spray-LbL technique is a simple method to produce functional thin film coatings.

  13. Development of a Convergent Spray Technologies(tm) Spray Process for a Solventless Sprayable Coating, MCC-1

    Science.gov (United States)

    Patel, Anil K.; Meeks, C.

    1998-01-01

    This paper discusses the application of Convergent Spray Technologies (TM) Spray Process to the development and successful implementation of Marshall Convergent Coating (MCC-1) as a primary Thermal Protection System (TPS) for the Space Shuttle Solid Rocket Boosters (SRBs). This paper discusses the environmental and process benefits of the MCC-1 technology, shows the systematic steps taken in developing the technology, including statistical sensitivity studies of about 35 variables. Based on the process and post-flight successes on the SRB, it will be seen that the technology is "field-proven". Application of this technology to other aerospace and commercial programs is summarized to illustrate the wide range of possibilities.

  14. CrCuAgN PVD nanocomposite coatings: Effects of annealing on coating morphology and nanostructure

    Science.gov (United States)

    Liu, Xingguang; Iamvasant, Chanon; Liu, Chang; Matthews, Allan; Leyland, Adrian

    2017-01-01

    CrCuAgN PVD nanocomposite coatings were produced using pulsed DC unbalanced magnetron sputtering. This investigation focuses on the effects of post-coat annealing on the surface morphology, phase composition and nanostructure of such coatings. In coatings with nitrogen contents up to 16 at.%, chromium exists as metallic Cr with N in supersaturated solid solution, even after 300 °C and 500 °C post-coat annealing. Annealing at 300 °C did not obviously change the phase composition of both nitrogen-free and nitrogen-containing coatings; however, 500 °C annealing resulted in significant transformation of the nitrogen-containing coatings. The formation of Ag aggregates relates to the (Cu + Ag)/Cr atomic ratio (threshold around 0.2), whereas the formation of Cu aggregates relates to the (Cu + Ag + N)/Cr atomic ratio (threshold around 0.5). The primary annealing-induced changes were reduced solubility of Cu, Ag and N in Cr, and the composition altering from a mixed ultra-fine nanocrystalline and partly amorphous phase constitution to a coarser, but still largely nanocrystalline structure. It was also found that, with sufficient Cu content (>12 at.%), annealing at a moderately high temperature (e.g. 500 °C) leads to transportation of both Cu and Ag (even at relatively low concentrations of Ag, ≤3 at.%) from inside the coating to the coating surface, which resulted in significant reductions in friction coefficient, by over 50% compared to that of the substrate (from 0.31 to 0.14 with a hemispherical diamond indenter, and from 0.83 to 0.40 with an alumina ball counterface, respectively). Results indicate that the addition of both Cu and Ag (in appropriate concentrations) to nitrogen-containing chromium is a viable strategy for the development of 'self-replenishing' silver-containing thin film architectures for temperature-dependent solid lubrication requirements or antimicrobial coating applications.

  15. Lead-free piezoelectric ceramic coatings fabricated by thermal spray process.

    Science.gov (United States)

    Yao, Kui; Chen, Shuting; Guo, Kun; Tan, Chee Kiang Ivan; Mirshekarloo, Meysam Sharifzadeh; Tay, Francis Eng Hock

    2017-09-04

    The paper starts from a review on the progress in fabrication of piezoelectric ceramic coatings by thermal spray method. For our experimental work, two types of lead-free piezoelectric ceramic coatings, including potassium sodium niobate (KNN)-based and bismuth sodium titanate (BNT)-based, are fabricated by thermal spray process, and their structure, morphology and piezoelectric properties are characterized. Our obtained lead-free ceramic coatings exhibit single phase of perovskite structure, relatively dense morphology, and competitive piezoelectric coefficients. The mechanism of forming the piezoelectric perovskite crystalline phase by thermal spray involving melting-recrystallization process is analyzed in comparison to that of ceramic synthesis through solid state reaction. Suppression of volatile loss and decomposition at high temperature due to the extremely high melting and cooling rate in the thermal spray process, and the impact on the resulting structure are discussed. Significant advantages of the thermal spray method over alternative processing methods for forming piezoelectric ceramic coatings are summarized. The combination of environmentally friendly lead-free compositions and the scalable thermal spray processing method will promote more applications of piezoelectric ceramic coatings for producing distributive sensors and transducers, and forming advanced smart structures and systems.

  16. The fabrication of carbon nanotubes reinforced copper coating by a kinetic spray process.

    Science.gov (United States)

    Xiong, Yuming; Kang, Kicheol; Yoon, Sanghoon; Lee, Changhee

    2008-10-01

    In this paper, multiwalled carbon nanotubes (MWCNTs) reinforced copper coating was deposited on copper sheet through kinetic spraying process. Effect of heat treatment on microstructure, conductivity, and hardness of the coating was investigated. The incompact MWCNTs reinforced copper coating exhibits a comparable hardness, but higher electrical resistivity than pure copper coating. After heat treatment at 600 degrees C for 2 h, the hardness of copper coatings significantly decreased due to the substantial grain growth. MWCNTs reinforced copper coating showed stable hardness and electrical conductivity against heat treatment owing to the inhibition of CNTs to grain growth and the intimate contact between CNTs and copper matrix.

  17. In vitro antibacterial and osteogenic properties of plasma sprayed silver-containing hydroxyapatite coating

    Institute of Scientific and Technical Information of China (English)

    RUAN HongJiang; FAN CunYi; ZHENG XueBin; ZHANG Yan; CHEN YiKai

    2009-01-01

    The objective of the present investigation was to characterize the antibacterial and osteogenic proper-ties of plasma sprayed silver-containing hydroxyapatite (HA/Ag) coating in vitro. HA/Ag coating was deposited via vacuum plasma spraying. The concentration of silver ions released from HA/Ag coating, the efficacy of the HA/Ag coating against bacterial biofilm development, the effect of the HA/Ag coating on early adhesion and ossification of osteoblast cells in vitro was measured. The silver ion concentra-tion released from the HA/Ag coating was between the minimum inhibitory concentration to bacteria and the cytotoxic concentration. Bacterial biofiim inhibition studies indicated an antibacterial activity on the HA/Ag coating surface when compared with hydroxyapatite (HA) coating alone. Moreover, it was demonstrated that osteoblast cell adhesion and mineralization occurred on the HA/Ag coating surface during the testing period. We conclude that the vacuum plasma sprayed HA/Ag coating possesses good antibacterial capability and osteogenic properties in vitro and represents a promising candidate for coating orthopedic implants.

  18. Effect of Laser Surface Treatment on the Corrosion Behavior of FeCrAl-Coated TZM Alloy

    Directory of Open Access Journals (Sweden)

    Jeong-Min Kim

    2016-01-01

    Full Text Available The current study involves the coating of Titanium-Zirconium-Molybdenum (TZM alloy with FeCrAl through plasma thermal spraying which proved effective in improving the oxidation resistance of the substrate. A post-laser surface melting treatment further enhanced the surface protection of the TZM alloy. Oxidation tests conducted at 1100 °C in air indicated that some Mo oxides were formed at the surface but a relatively small amount of weight reduction was observed for FeCrAl-coated TZM alloys up to 60 min of treatment. The post-laser surface treatment following the plasma thermal spray process apparently delayed the severe oxidation process and surface spalling of the alloy. It was suggested that the slow reduction in weight in the post-laser-treated specimen was related to fewer defects in the coating layer. It was also found that a surface reaction layer formed through the diffusion of Fe into the Mo alloy substrate at high temperature. The layer mainly consisted of Fe-saturated Mo and FeMo intermetallic compounds. In order to observe the corrosion behavior of the laser-treated alloy in 3.5% NaCl solution, electrochemical characteristics were also investigated. A proposed equivalent circuit model for the specimen indicated localized corrosion of coated alloy with some permeable defects in the coating layer.