Preparation and characterization of boron nitride coatings on carbon fibers from borazine by chemical vapor deposition

Boron nitride (BN) coatings were deposited on carbon fibers by chemical vapor deposition (CVD) using borazine as single source precursor. The deposited coatings were characterized by scanning electron microscopy (SEM), Auger electron spectroscopy (AES), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR) and Raman spectroscopy. The effect of temperatures on growth kinetics, morphology, composition and structure of the coatings was investigated. In the low temperature range of 900 °C-1000 °C, the growth rate increased with increasing temperature complying with Arrhenius law, and an apparent active energy of 72 kJ/mol was calculated. The coating surface was smooth and compact, and the coatings uniformly deposited on individual fibers of carbon fiber bundles. The growth was controlled by surface reaction. At 1000 °C, the deposition rate reached a maximum (2.5 μm/h). At the same time, the limiting step of the growth translated to be mass-transportation. Above 1100 °C, the growth rate decreased drastically due to the occurrence of gas-phase nucleation. Moreover, the coating surface became loose and rough. Composition and structure examinations revealed that stoichiometric BN coatings with turbostratic structure were obtained below 1000 °C, while hexagonal BN coatings were deposited above 1100 °C. A penetration of carbon element from the fibers to the coatings was observed.     

Influence of TaCl5 partial pressure on texture structure of TaC coating deposited by chemical vapor deposition

TaC was deposited on graphite substrate with different TaCl₅ partial pressure at 800 °C and 1200 °C by chemical vapor deposition. Microstructures and texture structures of the prepared coatings were researched with X-ray diffraction and scanning electronic microscopy. When the coating deposition process is controlled by surface reaction kinetics (800 °C), TaCl₅ partial pressure had little influence on the microstructure and texture structure of the coating. When the coating formation process is controlled by diffusion kinetics (1200 °C), the microstructure, texture structure of the prepared TaC grains vary greatly with TaCl₅ partial pressure. In the diffusion controlled process, the increasing of TaCl₅ partial pressure will result in the changing of gas supersaturation, and then the occurrence of secondary nucleation, which is the main reason for the changing of coating morphology and texture structure. With the help of competitive growth in (1 0 0) and (1 1 1) directions, the formation mechanism of the different texture coatings are discussed in detail. In addition, a diffusion model of deposition species around step-edge-corner was also proposed to explain the growth mechanism of the texture coatings.     

Texture structure and ablation behavior of TaC coating on carbon/carbon composites

TaC coatings with hybrid, (2 0 0) and (2 2 0) texture structure were prepared on carbon/carbon (C/C) composites by isothermal chemical vapor deposition with TaCl₅-Ar-C₃H₆ system. The residual stress, hardness and ablation behaviors of the different coatings were characterized by Raman spectra, nano-indentation and oxyacetylene flame ablation machine respectively. Results shown tensile stress exists in the TaC coatings and increases when texture orientation turns from hybrid to (2 2 0) and (2 0 0), while nano-indentation hardness of the coatings also obeys the same trend. The deposited coatings could improve the ablation-resistance properties of C/C composites effectively. The texture structure also had great effects on the ablation properties and ablation morphologies of the coatings. The mass ablation rate obviously decreases when the texture structure changes from hybrid orientation to (2 0 0) and (2 2 0) orientations. The hybrid orientation and (2 0 0) texture coatings exhibit coarse oxide morphologies with crater or some breakage existed; while the (2 2 0) texture coating shows dense, molten oxide morphology. The main ablation behaviors of the hybrid, (2 0 0) and (2 2 0) texture TaC coatings are oxidation and particle denudation and block denudation, oxidation and block denudation, oxidation and mechanical erosion and block denudation, respectively.     

Characterization of electrochemically deposited polyaniline–polypyrrole blend coatings on carbon fibers

Macroscopically homogeneous and uniform coatings of polyaniline, polypyrrole and their blend were successfully deposited on carbon fibers by aqueous electropolymerization technique. Electrochemical polymerization of aniline and pyrrole blend with p-toluene sulfonic acid as the electrolyte was carried out by cyclic voltammetry in the potential range of -0.2 V to 1.0 V vs. SCE. The electrochemical polymerization parameters such as the molar feed ratio of monomers and number of cycles were systematically varied. Gravimetric analysis showed that the amount of blend coatings on carbon fibers was dependant on the electrochemical deposition parameters. As the pyrrole concentration in the feed increases, the deposition rate increases. Analysis of the blend coating on the carbon fibers by infrared spectrophotometry (IR) showed that both polyaniline and polypyrrole are present in the coating. The morphology of composite coating varied from smooth to rough and globular structure during deposition.     

Characterization of oxide coatings formed on tantalum by plasma electrolytic oxidation in 12-tungstosilicic acid

Oxide coatings were formed on tantalum by plasma electrolytic oxidation (PEO) process in 12-tungstosilicic acid. The PEO process can be divided into three stages with respect to change of the voltage-time response. The contribution of electron current density in total current density during anodization results in the transformation of the slope of voltage-time curve. The surface morphology, chemical and phase composition of oxide coatings were investigated by AFM, SEM-EDX, XRD and Raman spectroscopy. Oxide coating morphology is strongly dependent of PEO time. The elemental components of PEO coatings are Ta, O, Si and W. The oxide coatings are partly crystallized and mainly composed of WO₃, Ta₂O₅ and SiO₂. Raman spectroscopy showed that the outer layer of oxide coatings formed during the PEO process is silicate tungsten bronze.     

Strength measurements of silica optical fibers under severe environment

Optical fibers are key components in telecommunication technologies. Apart from optical specifications, optical fibers are expected to keep most of their physical properties for 10–20 years in current operating conditions. The reliability and the expected lifetime of optical links are closely related to action of the chemical environment on the silica network. However, the coating also contributes largely to the mechanical properties of the fibers.The aim of this work was to study the strength and the mechanical behavior of the silica optical fibers in an acid environment and with a permanent deformation. A container with ammonium bifluoride acid salt was plunged into hot water at different temperatures (55 and 75 °C). This emitted acid vapors which attacked the optical fibers for a period of 1–18 days. An aging study was performed on silica optical fibers with standard polyacrylate coating and with hermetic carbon coating. A dynamic two-point bending bench at different faceplate velocities (100, 200, 400 and 800 μm/s) was used. For comparison, the same dynamic measurements were also carried out on non-aged fibers.After acid vapor condensation, salt crystal deposits on the fibers were displayed using an electron scanning microscope. These crystals became visible to the naked eye from the seventh day.     

Synthesis of boron nitride coatings on quartz fibers: Thickness control and mechanism research

Boron nitride (BN) coatings were successfully synthesized on quartz fibers by dip-coating in boric acid and urea solutions at 700 °C. The SEM micrographs indicated that the quartz fibers were fully covered by coatings with smooth surface. The XRD, FT-IR, XPS spectra and HR-TEM results showed that the composition of the coatings which combined closely with the quartz fibers was polycrystalline h-BN. By changing the dip circles, the coating thickness was well controlled. The thicknesses of samples dipped less than six circles increased linearly with dipping-circles; and the increment of coating thickness would slow down when the fibers were dipped 10 circles. After being dipped for 10 circles, the thickness was about 300 nm. The coating thickness was also established by calculation and the calculated results were consistent with the results measured by micrograph.     

Preparation of the Ni-P composite coating co-deposited by nano TiC particles and evaluation of it's corrosion property

In current research, low carbon steel plates were coated by Ni-P electroless method. The effect of adding different concentrations (ranging from 0.01 g/l to 0.5 g/l) of TiC nano-sized particles to the plating bath on deposition rate, surface morphology and corrosion behavior of Ni-P-TiC composite coatings were investigated. The surface morphology and the relevant structure were evaluated by scanning electron microscopy (SEM) and X-ray diffraction (XRD). Corrosion behavior of the coated steel was evaluated by electrochemical impedance spectroscopy (EIS) and polarization techniques. The results showed that addition of TiC nano-particles to Ni-P electroless bath not only changes the surface morphology of Ni-P coating, but also improves corrosion resistance of the steel in comparison with TiC free Ni-P electroless coating. In addition, the deposition rate of coating was also affected by incorporation of TiC particles. It was also found that improvement in corrosion resistance largely depends on the phosphorous and TiC concentrations on the coatings.     

Process and performance of hot dip zinc coatings containing ZnO and Ni-P under layers as barrier protection

A new coating system of under layer for hot dip zinc coating was explored as an effective coating for steel especially for application in relatively high aggressive environments. The influence of different barrier layers formed prior to hot dip galvanization was investigated to optimize high performance protective galvanic coatings. The deposition of ZnO and Ni-P inner layers and characteristics of hotdip zinc coatings were explored in this study. The coating morphology was characterized by scanning electron microscope (SEM) analysis. The hot dip zinc coatings containing under layer showed substantial improvement in their properties such as good adhesion, and high hardness. In addition, a decrease in the thickness of the coating layer and an enhancement of the corrosion resistance were found. Open circuit potential (OCP) of different galvanized layers in different corrosive media viz. 5% NaCl and 0.5 M H₂SO₄ solutions at 25 ± 1 °C was measured as a function of time. A nobler OCP was exhibited for samples treated with ZnO and Ni than sample of pure Zn; this indicates a dissolution process followed by passivation due to the surface oxide formation. The high negative OCP can be attributed to the better alloying reaction between Zn and Fe and to the sacrificial nature of the top pure zinc layer.     

Comparative impact of doping nano-conducting polymer with carbon and carbon oxide composites in alkyd binder as anti-corrosive coatings

This study concentrated on producing anticorrosive coating depending on alkyd resin blended with polyaniline-carbon allotropes composites as filler. Polyaniline (PANI) and its composites were produced by doping of PANI with the carbon allotropes (graphene and multi-walled carbon nanotubes) and carbon-oxide allotropes (graphene oxide and multi-walled carbon nanotubes oxide) in different ratios through in situ chemical polymerization. The morphology of PANI and its composites were examined by transmission electron microscope (TEM), which proved that PANI composites appeared as a shell layer in core/shell structure with various overlay thickness depending on the adsorption type for polyaniline. The performance of the prepared coatings in cabinet salt agrees with electrical conductivity values where the best PANI/composite in conductivity value is the most efficient as an anti-corrosive coating.     

Converting ultrasonic induction heating deposited monetite coating to Na-doped HA coating on H2O2-treated C/C composites by a two-step hydrothermal method

a monetite coating on H₂O₂-treated C/C composites was prepared by ultrasonic induction heating (UIH) technology. Subsequently, this coating was subjected to an ammonia hydrothermal treatment to form a undoped hydroxyapatite (U-HA) coating. Finally, the as-prepared U-HA coating was placed in a NaOH solution and hydrothermally treated to produce the other hydroxyapatite (Na-HA) coating. The structure, morphology and chemical composition of the two HA coatings were characterized by XRD, FTIR, SEM and EDS, the adhesiveness and local mechanical properties, e.g. nanohardness and Young's modulus of the two HA coatings to C/C composites was evaluated by a scratch test and nanoindentation technique respectively. The results showed that the two HA coatings had the alike morphology and crystallization. But, compared with the U-HA coating, the Na-HA coating was doped with Na ions, and gave a Ca/P ratio close to a stoichiometric hydroxyapatite, and thus showed a higher nano-indentation value, Young's modulus, and larger bonding strength. These results verified the strengthened effect of Na ion in hydroxyapatite coating on carbon/carbon (C/C) composities.     

Ta/Ni/Ta multilayered ohmic contacts on n-type SiC

The interface formation, electrical properties and the surface morphology of multilayered Ta/Ni/Ta/SiC contacts were reported in this study. It was found that the conducting behavior of the contacts so fabricated is much dependent on the metal layer thickness and the subsequent annealing temperature. Auger electron spectroscopy (AES) and X-ray diffraction analyses revealed that Ni₂Si and TaC formed as a result of the annealing. The Ni atoms diffused downward to metal/SiC interface and converted into Ni₂Si layer in adjacent to the SiC substrate. The released carbon atoms reacted with Ta atoms to form TaC layer. Ohmic contacts with specific contact resistivity as low as 3 × 10⁻⁴ Ω cm² have been achieved after thermal annealing. The formation of carbon vacancies at the Ni₂Si/SiC interface, probably created by dissociation of SiC and formation of TaC during thermal annealing, should be responsible for the ohmic formation of the annealed Ta/Ni/Ta contacts. The addition of Ta into the Ni metallization scheme to n-SiC restricted the accumulation of carbon atoms left behind during Ni₂Si formation, improving the electrical and microstructure properties.     

Tungsten and iridium multilayered structure by DGP as ablation-resistance coatings for graphite

Oxidation protection of carbon material under ultra-high temperature is a serious problem. In this paper, a newly designed multilayer coating of W/Ir was produced onto the graphite substrate by double glow plasma. As comparison, the Ir single-layer coating on the graphite was also prepared. The ablation property and thermal stability of the coatings were studied at 2000 °C in an oxyacetylene torch flame. Ablation tests showed that the coated graphite substrates were protected more effectively by W/Ir multilayer coating than Ir single-layer coating. Ir single-layer coating after ablation kept the integrality, although there was a poor adhesion of the Ir coating to the graphite substrate because of the thermal expansion mismatch and the non-wetting of the carbon by Ir coating. The mass loss rate of the W/Ir-coated specimen after ablation was about 1.62%. The interface of W/Ir multilayer coating and the graphite substrate exhibited good adherence no evidence of delamination after ablation. W/Ir multilayer coating could be useful for protecting graphite in high-temperature application for a short time.     

Failure of thin films: Optical shearography versus electrochemical impedance spectroscopy

In the present work, the temperature versus thermal deformation (strain) with respect to time, of different coating films, was studied by a non-destructive technique (NDT) known as shearography. An organic coating, i.e., ACE Premium Enamel, on a metallic alloy, i.e., a carbon steel, was investigated at a temperature range simulating the severe weather temperatures in Kuwait, especially between the daylight and the nighttime temperatures, 20-60 °C. The investigation focused on determining the in-plane displacement of the coating, which amounts to the thermal deformation (strain) with respect to the applied temperature range. Furthermore, the investigation focused on determining the thermal expansion coefficients of coatings, the slope of the plot of the thermal deformation (strain) versus the applied temperature range. In other words, one could determine, from the decreasing value of the thermal expansion coefficients of coatings, a critical (steady state) value of the thermal expansion coefficients of coatings, in which the integrity of the coatings can be assessed with respect to time. In fact, determination of the critical (steady state) value of the thermal expansion coefficients of coatings could be accomplished independent of parameters, i.e., ultraviolet (UV) exposure, humidity, and exposure to chemical species, which normally are considered in conventional methods of assessing the integrity of coatings. Furthermore, results of shearography indicate that the technique is a very useful NDT method not only to determine the critical value of the thermal expansion coefficients of different coatings but also to be used as a 2D-microscope for monitoring the deformation of the coatings in real time at a submicroscopic scale. Also, the obtained data of the shearography technique were compared with data obtained by electrochemical impedance spectroscopy (EIS) in an aqueous solution of 3% NaCl.     

In situ formation of low friction ceramic coatings on carbon steel by plasma electrolytic oxidation in two types of electrolytes

In situ formation of ceramic coatings on Q235 carbon steel was achieved by plasma electrolytic oxidation (PEO) in carbonate electrolyte and silicate electrolyte, respectively. The surface and cross-section morphology, phase and elemental composition of PEO coatings were examined by means of scanning electron microscopy (SEM), X-ray diffraction (XRD) and energy-dispersive X-ray spectroscopy (EDS). The bond strength of the coating was determined using a direct pull-off test. The hardness as well as tribological properties of the ceramic coating was primarily studied. The results indicated that the coating obtained in carbonate electrolyte was Fe₃O₄, while the coating achieved from silicate electrolyte was proved to be amorphous. Both kinds of coatings showed coarse and porous surface. The Fe₃O₄ coatings obtained in carbonate electrolyte showed a high bonding strength to the substrate up to 20 ± 2 MPa and the value was 15 ± 2 MPa for the amorphous coatings obtained in carbonate electrolyte. The micro hardness of the amorphous coating and the Fe₃O₄ coating was 1001 Hv and 1413 Hv, respectively, which was more than two and three times as that of the Q235 alloy substrate (415 Hv). The friction coefficient exhibited by amorphous coating and Fe₃O₄ coating was 0.13 and 0.11, respectively, both lower than the uncoated Q235 substrate which ranged from 0.17 to 0.35.     

Effects of Ta on microstructure and microhardness of Ni based laser clad coating

Through addition of Tantalum, fine TaC particles were in situ synthesized in a NiCrBSi alloy laser clad composite coating. Microstructure, microhardness and abrasive wear resistance of the composite coating were investigated. The result showed that TaC particles were dispersed in Ni based alloy composite coating, refining the microstructure of the coating after laser cladding. Amount of coarse primary carbides such as M7C3 and eutectic of γ-Ni + M23C6 substantially decreased because the formation of TaC particles suppressed the formation of M7C3 and M23C6. On the one hand, fine TaC particles acted as hard phase, which improved the microhardness of the composite coating; on the other hand, a decrease in amount of the coarse M7C3 and eutectic of γ-Ni + M23C6 reduced the crack susceptibility of the Ni based composite coating. Also, Ta element improved the abrasive wear resistance of the Ni based coating.     

New concept of failure of thin organic films

A critical (steady state) value of the thermal expansion coefficients of different coatings was determined by a nondestructive technique (NDT) known as laser shearography. The behavior of organic coatings, i.e., ACE premium-grey enamel, a yellow acrylic lacquer, and a gold nail polish on a metallic alloy, i.e., a carbon steel, was investigated over a temperature range of 20–60 °C. The value of the thermal expansion coefficients of coatings was derived from the slope of the plot of the thermal deformation (strain) versus the applied temperature. The integrity of the coatings with respect to time was assessed by comparison the measured coefficients of thermal expansion (CTE) to the critical (steady state) or asymptotic value of CTE. By shearography, measurement of coating properties could be performed independent of parameters such as UV exposure, humidity, presence of chemical species, and other parameters which may normally interfere with conventional methods of the assessing of the integrity of coatings. Therefore, one may measure CTE of coatings, regardless of the history of the coating, in order to assess the integrity of coatings. Also, the obtained shearography data were found to be in a reasonable trend with the data of electrochemical impedance spectroscopy (EIS) in 3%NaCl solution.     

Formation and structure of sphene/titania composite coatings on titanium formed by a hybrid technique of microarc oxidation and heat-treatment

Sphene/titania composite coatings were fabricated on titanium by a hybrid technique of microarc oxidation (MAO) and heat treatment. The high-applied voltages promote the formation of sphene in the MAO coatings after heat-treatment. Heat treatment could change the surface morphology of the MAO coatings such as roughness, macropores size and density and the thickness of the MAO coatings. Increasing the heat-treatment temperature decreased the atomic concentration ratios of Ti/Si and Ti/Ca of the MAO coatings. The chemical states of Ti⁴⁺, Ca²⁺, Si²⁺ and O²⁻ were observed on all the coatings. Additionally, Ti²⁺ was detected in the MAO and heat-treated MAO coatings at 600 and 700 °C. The heat-treatment has obvious effect on the chemical states of Si, Ti and O elements due to the formation of sphene and oxidation of TiO phase of the MAO coating, but did not affect that of Ca. In the heat-treated MAO coatings at 800 °C (MAO-H8), the titanium surface shows a MAO top layer and oxidized interior layer. A concentration gradient in components in the MAO layer of the MAO-H8 coating was formed.     

Antistatic behavior of PAN-based low-temperature carbonaceous fibers

A kind of antistatic coatings which were applied to nonconductive surfaces were prepared with polytetrafluoroethylene (PTFE) paint as matrix, polyacrylonitrile (PAN)-based low-temperature carbonaceous fibers as conductive filler. The influences of carbonaceous fiber content, carbonization temperature, size and testing voltage on the surface resistivity of the coating were investigated. The surface resistivity could be well controlled in the static dissipative range (10⁶–10⁹ Ω) by changing the content, size and carbonization temperature of carbonaceous fibers. The present study could be useful for the application of chopped carbonaceous fibers in antistatic materials.     

The effect of cerium oxide argon-annealed coatings on the high temperature oxidation of a FeCrAl alloy

Ceria coatings were applied in order to improve the adherence of alumina scales developed on a model Fe–20Cr–5Al alloy during oxidation at high temperature. These coatings were performed by argon annealing of a ceria sol–gel coating at temperatures ranging between 600 and 1000 °C. The influence of these coatings on the alloy oxidation behaviour was studied at 1100 °C. In situ X-ray diffraction (XRD) was performed to characterize the coating crystallographic nature after annealing and during the oxidation process. The alumina scale morphologies were studied by means of scanning electron microscopy (SEM) coupled with energy dispersive X-ray spectroscopy (EDS). The present work shows that the alumina scale morphology observed on cerium sol–gel coated alloy was very convoluted. On the cerium sol–gel coated alloy, argon annealing results in an increase of the oxidation rate in air, at 1100 °C. The 600 °C argon annealing temperature results in a good alumina scale adherence under thermal cycling conditions at 1100 °C.