Formation of Al2O3 coatings on NiTi alloy by micro-arc oxidation method

Rough and porous Al₂O₃ coatings containing Ca and P were prepared on Ti–50.8 at.% Ni alloy by micro-arc oxidation (MAO) technique. The microstructure, elemental and phase composition of the coatings were investigated by scanning electron microscopy (SEM), energy dispersive X-ray spectrometer (EDS) and thin-film X-ray diffraction (TF-XRD). The thickness of the coatings was measured by eddy current coating thickness gauge. The corrosion resistance and the nickel release of the coated and uncoated samples were examined by potentiodynamic polarization tests and immersion tests in Hank’s solution, respectively. The results show that the coatings are mainly composed of γ-Al₂O₃ crystal phase. The Ni content of the coatings is about 3.5 at.%, which is greatly lower than that of NiTi substrate. With increasing treatment time, both thickness and roughness of the coatings increase. The corrosion resistance of the coated samples is about two orders of magnitude higher than that of the uncoated NiTi alloy. The concentration of Ni released from coated NiTi samples is much lower than that of uncoated NiTi sample. It can be reduced in the factor of one-seventh compared with the uncoated NiTi sample after 3 weeks immersion in Hank’s solution.     

Preparation and properties of titanium oxide film on NiTi alloy by micro-arc oxidation

Titanium oxide ceramic coatings were prepared by micro-arc oxidation (MAO) in galvanostatic regime on biomedical NiTi alloy in H₃PO₄ electrolyte using DC power supply. The surface of the coating exhibited a typical MAO porous and rough structure. The XPS analysis indicated that the coatings were mainly consisted of O, Ti, P, and a little amount of Ni, and the concentration of Ni was greatly reduced compared to that of the NiTi substrate. The TF-XRD analysis revealed that MAO coating was composed of amorphous titanium oxide. The coatings were tightly adhesive to the substrates with the bonding strength more than 45 MPa, which was suitable for medical applications. The curves of potentiodynamic porlarization indicated that the corrosion resistance of NiTi alloy was significantly improved due to titanium oxide formation on NiTi alloy by MAO.     

Microstructure and mechanical properties of alumina coatings prepared by double glow plasma technique

Low-temperature growth (600 °C) of α-Al₂O₃ coatings on the stainless steel substrate by double glow plasma technique was achieved. The compositions and microstructures of the coatings prepared at different oxygen flow rates were characterized, respectively, by X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive X-ray (EDX) spectrometry. A phenomenological mechanism for the formation of the Al₂O₃ ceramic coatings during the oxidation process was proposed on the basis of the experimental results. It was obvious that the oxygen flow rates had a great effect on the surface structure of the prepared Al₂O₃ coatings. The dense and smooth Al₂O₃ coatings were prepared at the oxygen flow rate of 15 sccm. In addition, the correlations between the mechanical properties of Al₂O₃ coating and oxygen flow rates were also discussed. The coating prepared at 15 sccm oxygen flow rate exhibited the best mechanical properties with a maximum hardness of 31 GPa and elastic modulus of 321 GPa. The corresponding critical load of scratch adherence for this sample was 47 N.     

Preparation and high-temperature properties of Au nano-particles doped α-Al2O3 composite coating on TiAl-based alloy

Au nano-particles doped α-Al₂O₃ composite coatings were successfully prepared on TiAl-based alloy by electrodeposition, using the Al₂O₃ sols with minor addition of HAuCl₄ solution. The even distribution of Au nano-particles (<2.0 wt.%) in the α-Al₂O₃ matrix has been observed. Isothermal oxidation tests of the samples coated with the as-prepared novel coatings at 900 °C in static air for 200 h shown that the oxygen inward diffusion can be effectively suppressed to a low level. The results of high-temperature cyclic oxidation test at 900 °C in air revealed that the oxidation and spallation resistance of TiAl-based alloy were improved significantly under thermal cycling. In the as-prepared coatings, cracks were shielded by means of crack bridging and the fracture resistance of the formed scales can be improved by toughening effects of the composite structure. Surface scratching tests after the cyclic oxidation exhibited that the adhesion of the formed composite scale on TiAl-based alloy was remarkably improved by the Au nano-particles doped α-Al₂O₃ composite coating.     

Surface chemistry and catalytic activity of Ni/Al2O3 irradiated with high-energy electron beam

The radiation effects induced effects by electron beam (EB) treatment on the catalytic activity of Ni/γ-Al₂O₃ were studied for the carbon dioxide reforming of methane with different EB energy and absorbed radiation dose. Transmission electron microscope (TEM), X-ray diffraction (XRD) and X-ray photoelectron spectroscopy (XPS) were used to determine the change in structure and surface states of Ni/γ-Al₂O₃ catalyst before and after the EB treatment. Higher energy EB treatment is useful for increasing the proportion of the active sites (such as Ni⁰ and NiAl₂O₄-phase) on the surface. The increase of Ni/Al-ratio indicates that the Ni dispersion on the surface increased with the EB-treatment, resulting in an increase of the active sites, which leads to improving the catalytic activity. XPS measurement also showed a decrease of the surface carbon with EB dose. The maximum 20% increase in the conversion of CO₂/CH₄-mixture into CO/H₂ gas was observed for the catalyst treated with 2 MeV energy and 600 kGy dose of EB relative to untreated.     

Thermal stability of alumina thin films containing γ-Al2O3 phase prepared by reactive magnetron sputtering

The paper reports on thermal stability of alumina thin films containing γ-Al₂O₃ phase and its conversion to a thermodynamically stable α-Al₂O₃ phase during a post-deposition equilibrium thermal annealing. The films were prepared by reactive magnetron sputtering and subsequently post-deposition annealing was carried out in air at temperatures ranging from 700 °C to 1150 °C and annealing times up to 5 h using a thermogravimetric system. The evolution of the structure was investigated by means of X-ray diffraction after cooling down of the films. It was found that (1) the nanocrystalline γ-Al₂O₃ phase in the films is thermally stable up to 1000 °C even after 5 h of annealing, (2) the nanocrystalline θ-Al₂O₃ phase was observed in a narrow time and temperature region at ≥1050 °C, and (3) annealing at 1100 °C for 2 h resulted in a dominance of the α-Al₂O₃ phase only in the films with a sufficient thickness.     

Annealing effects on the optical and structural properties of Al2O3/SiO2 films as UV antireflection coatings on 4H-SiC substrates

Al₂O₃/SiO₂ films have been prepared by electron-beam evaporation as ultraviolet (UV) antireflection coatings on 4H-SiC substrates and annealed at different temperatures. The films were characterized by reflection spectra, ellipsometer system, atomic force microscopy (AFM), X-ray diffraction (XRD) and X-ray photoelectron spectroscopy (XPS), respectively. As the annealing temperature increased, the minimum reflectance of the films moved to the shorter wavelength for the variation of refractive indices and the reduction of film thicknesses. The surface grains appeared to get larger in size and the root mean square (RMS) roughness of the annealed films increased with the annealing temperature but was less than that of the as-deposited. The Al₂O₃/SiO₂ films maintained amorphous in microstructure with the increase of the temperature. Meanwhile, the transition and diffusion in film component were found in XPS measurement. These results provided the important references for Al₂O₃/SiO₂ films annealed at reasonable temperatures and prepared as fine antireflection coatings on 4H-SiC-based UV optoelectronic devices.     

Structure and surface properties of praseodymium modified alumina

Mixed PrO₂-Al₂O₃ oxides with different PrO₂ content (1-20 wt.%) were prepared by wetness impregnation of γ-alumina with aqueous solution of praseodymium nitrate. The samples were characterized by different techniques, using surface adsorption-desorption of N₂ (S_BET), thermogravimetric analysis (TGA), X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), UV-vis diffuse reflectance spectroscopy (DRS), temperature-programmed reduction (TPR) and temperature-programmed desorption of CO₂ (TPD-CO₂). TGA and XRD showed the presence of small praseodymium oxide species on the alumina surface. XPS and DRS detected electron deficient interaction between deposited praseodymium oxide and alumina. It was observed a lower reduction temperature for supported Pr oxide species compared to that of the bulk Pr₆O₁₁. TPD-CO₂ studies suggested that the deposition of Pr oxide on alumina leaded to increase of the basicity of mixed oxides.     

Nickel deposition on γ-Al2O3 model catalysts: An experimental and theoretical investigation

Recently, surface modifications on a commercial Ni/γ-Al₂O₃ catalyst during the production of methane from synthesis gas were investigated by quasi insitu X-ray photoelectron spectroscopy (XPS) [I. Czekaj, F. Loviat, F. Raimondi, J. Wambach, S. Biollaz, A. Wokaun, Appl. Catal. A: Gen. 329 (2007) 68]. The conclusion was that the reactivity and the observed reaction mechanisms on the different Ni particles are influenced directly by both the size and the composition of the particles on the γ-Al₂O₃ support.In this investigation, Ni deposition and cluster growth on model catalyst samples (10 nm thick, polycrystalline γ-Al₂O₃ on Si(100)) were investigated by XPS. Several steps in the binding energy during Ni deposition indicate changes in the cluster growth. The molecular structure of the catalyst was investigated using Density Functional Theory calculations (StoBe) with a cluster model and non-local functional (RPBE) approach. An Al₁₅O₄₀H₃₅ cluster was selected to represent the γ-Al₂O₃(100) surface. Ni clusters of different size were cut from a Ni(100) surface and deposited on the Al₁₅O₄₀H₃₅ cluster in order to validate the deposition model determined by XPS.     

Ultra-hard ceramic coatings fabricated through microarc oxidation on aluminium alloy

Ultra-hard ceramic coatings with microhardness of 2535 Hv have been synthesized on the Al alloy substrate by microarc oxidation (MAO) technique. The effects of anodic current density (j_a) and the ratio of cathodic to anodic current density (j_c/j_a) on the mechanical and corrosion resistance properties of MAO coatings have been studied by microhardness and pitting corrosion tests, respectively. In addition, the phase composition and microstructure of the coatings were analyzed by X-ray diffraction (XRD) and scanning electron microscopy (SEM), respectively. The results show that the coatings prepared at high anodic current density consist mainly of α-Al₂O₃, while those fabricated at low anodic current density are almost composed of γ-Al₂O₃. Microhardness test shows that the coatings have high microhardness, and the highest one is found in the coating formed at j_a = 15 A/dm² and j_c/j_a = 0.7. Pitting corrosion test shows that the structure of coatings is strongly influenced by the varying j_c/j_a.     

X-ray photoelectron spectroscopy of nano-multilayered Zr-O/Al-O coatings deposited by cathodic vacuum arc plasma

Nano-multilayered Zr-O/Al-O coatings with alternating Zr-O and Al-O layers having a bi-layer period of 6-7 nm and total coating thickness of 1.0-1.2 μm were deposited using a cathodic vacuum arc plasma process on rotating Si substrates. Plasmas generated from two cathodes, Zr and Al, were deposited simultaneously in a mixture of Ar and O₂ background gases. The Zr-O/Al-O coatings, as well as bulk ZrO₂ and Al₂O₃ reference samples, were studied using X-ray photoelectron spectroscopy (XPS). The XPS spectra were analyzed on the surface and after sputtering with a 4 kV Ar⁺ ion gun. High resolution angle resolved spectra were obtained at three take-off angles: 15°, 45° and 75° relative to the sample surface.It was shown that preferential sputtering of oxygen took place during XPS of bulk reference ZrO₂ samples, producing ZrO and free Zr along with ZrO₂ in the XPS spectra. In contrast, no preferential sputtering was observed with Al₂O₃ reference samples. The Zr-O/Al-O coatings contained a large amount of free metals along with their oxides. Free Zr and Al were observed in the coating spectra both before and after sputtering, and thus cannot be due solely to preferential sputtering.Transmission electron microscopy revealed that the Zr-O/Al-O coatings had a nano-multilayered structure with well distinguished alternating layers. However, both of the alternating layers of the coating contained of a mixture of aluminum and zirconium oxides and free Al and Zr metals. The concentration of Zr and Al changed periodically with distance normal to the coating surface: the Zr maximum coincided with the Al minimum and vice versa. However the concentration of Zr in both alternating layers was significantly larger than that of Al. Despite the large free metal concentration, the Knoop hardness, 21.5 GPa, was relatively high, which might be attributed to super-lattice formation or formation of a metal-oxide nanocomposite within the layers.     

Laser surface remelting of plasma sprayed nanostructured Al2O3-13wt%TiO2 coatings on titanium alloy

Plasma sprayed nanostructured coatings were successfully fabricated on a titanium alloy (Ti-6Al-4V) substrate using the as-prepared nanostructured Al₂O₃-13wt%TiO₂ feedstock. A CO₂ laser was used to remelt the plasma sprayed coatings. The effects of laser remelting on the phase constituents, microstructure and properties of the ceramic coatings were investigated. The laser remelted coatings (LRmC) possessed a much denser and more homogenous structure and excellent metallurgical bonding to the substrate. The average porosity of the LRmC was reduced to 0.9%, compared with 6.2% of the as-sprayed coatings. The net-like structure in the as-prepared feedstock remained in the coatings before and after laser remelting. The metastable γ-Al₂O₃ phase in the as-sprayed coatings transformed to stable α-Al₂O₃ during laser remelting. The LRmC could remain nanostructure. The microhardness of the coatings was enhanced to 1000-1400 HV_0.3 after laser remelting, which was much higher than that of the plasma sprayed coatings and 2-3 times higher that of the substrate. Significant decreases in surface roughness were also found in the LRmC.     

Influence of FeSO4 concentration on thermal emissivity of coatings formed on titanium alloy by micro-arc oxidation

Ceramic coatings with high emission were fabricated on Ti6Al4V alloy by microarc oxidation (MAO) with additive FeSO₄ into the electrolyte. The microstructure, chemical composition and chemical state of the coatings were determined by SEM, XRD, EDS and XPS, respectively. The bonding strength between the coating and substrate was studied by tensile strength test, together with the thermal shock resistance of the coating. The results showed that Fe content in the coating layer significantly affect its thermal emissivity. The relative content of Fe in the coatings surface increased at first and then decreased with increasing the concentration of FeSO₄ in electrolytes, so does the emissivity of the coatings. The bonding strength became weaker with increasing the concentration of FeSO₄. In addition, the coating remains stable over 40 cycles of thermal shocking. The coating formed at 3 g/L FeSO₄ demonstrates the highest an average spectral emissivity value around of 0.87, and bonding strength higher than 33 MPa.     

Low-temperature deposition of α-Al2O3 films by laser chemical vapor deposition using a diode laser

We prepared Al₂O₃ films by laser chemical vapor deposition (LCVD) using a diode laser and aluminum acetylacetonate (Al(acac)₃) precursors and investigated the effects of laser power (P_L), deposition temperature (T_dep), and total pressure (P_tot) in a reaction chamber on the crystal phase, microstructure, and deposition rate (R_dep). An amorphous phase was obtained at P_L = 50 W, whereas an α-phase was obtained at P_L > 100 W. At P_L = 150 and 200 W (1 0 4)- and (0 1 2)-oriented α-Al₂O₃ films were obtained, respectively. The R_dep of α-Al₂O₃ films increases with decreasing P_L and P_tot. Single-phase α-Al₂O₃ film was obtained at T_dep = 928 K, which is about 350 K lower than that obtained by conventional thermal CVD using Al(acac)₃ precursor.     

Influence of hydrothermally modified γ-Al2O3 on the properties of NiMo/γ-Al2O3 catalyst

The influence of hydrothermal modification of γ-Al₂O₃ on the properties of NiMo/γ-Al₂O₃ catalyst was investigated in this paper. The experimental results showed that the use of the modified γ-Al₂O₃ in the preparation of the NiMo/γ-Al₂O₃ catalyst led to the increase of the dispersion of the surface Mo and Ni oxides, favored the formation of the poly-molybdates and promoted the reduction of the active Mo oxides owing to the increase of the surface acidity of the modified γ-Al₂O₃. Therefore, the NiMo/γ-Al₂O₃ catalyst supported on the modified γ-Al₂O₃ exhibited a higher hydrodenitrogenation (HDN) activity than that supported on the untreated γ-Al₂O₃ in the temperature range of 300-340 °C.     

Microstructure and properties of Ni-Co/nano-Al2O3 composite coatings by pulse reversal current electrodeposition

Ni-Co/nano-Al₂O₃ (Ni-Co/Al₂O₃) composite coatings were prepared under pulse reversal current (PRC) and direct current (dc) methods respectively. The microstructure of coatings was characterized by means of XRD, SEM and TEM. Both the Ni-Co alloy and composite coatings exhibit single phase of Ni matrix with face-centered cubic (fcc) crystal structure, and the crystal orientation of the Ni-Co/Al₂O₃ composite coating was transformed from crystal face (2 0 0) to (1 1 1) compared with alloy coatings. The hardness, anti-wear property and macro-residual stress were also investigated. The results showed that the microstructure and performance of the coatings were greatly affected by Al₂O₃ content and the electrodeposition methods. With the increasing of Al₂O₃ content, the hardness and wear resistance of the composite coatings enhanced. The PRC composite coatings exhibited compact surface, high hardness, better wear resistance and lower macro-residual stress compared with that of the dc composite coatings.     

Influences of laser remelting on microstructure of nanostructured Al2O3-13 wt.% TiO2 coatings fabricated by plasma spraying

The effects of laser remelting on microstructure of nanostructured Al₂O₃-13 wt.% TiO₂ ceramic coatings prepared by plasma spraying with agglomerated powders were studied. The microstructure of the feedstock, as-sprayed and laser-remelted coatings were investigated by using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and X-ray diffractometry (XRD). The results indicate that the plasma-sprayed ceramic coating consists of both fully melted regions and partially melted regions. The totally ceramic coating, especially the fully melted regions, has a typical plasma-sprayed lamellar-like structure as the conventional coating, and has some pores. According to the difference of microstructures, the partially melted regions can be divided into liquid-phase sintered regions (a three-dimensional net or skeleton-like structure: Al₂O₃-rich submicron particles embedded in the TiO₂-rich matrix) and solid-phase sintered regions (remained nanoparticles). The lamellar defect of the as-sprayed coating is erased, and the compactness of the coating is improved significantly after laser remelting. The laser-remelted region composed of fine equiaxed grains, which are different from the conventional column-like crystals along the direction of the heat current. Due to the rapid solidification of laser remelting process, there are still some nanoparticles in the remelted region because of an insufficient time for grains growth.     

Effect of hydrothermal treatment on the acidity distribution of γ-Al2O3 support

The influence of hydrothermal treatment on the total acidity and the acidity distribution of γ-Al₂O₃ were studied in this paper. The experimental results indicated that the hydrothermal treatment of γ-Al₂O₃ at moderate condition (140 °C, 1.0-24.0 h) led to the formation of the plate-like γ-AlOOH crystallites with different morphologies, which resulted in the change of the surface acidity of the corresponding γ-Al₂O₃ supports. The increase of the reaction time in the period of 1.0-2.0 h led to the increase of the specific surface area, the surface OH, the total acidity and the ratio of the weak acidity in the acidity distribution of γ-Al₂O₃. The further prolongation of reaction time caused the overgrowth of γ-AlOOH crystallites, leading to the decrease of the specific surface area, the surface OH and the total acidity of the corresponding γ-Al₂O₃.     

Evolution of micro-arc oxidation behaviors of the hot-dipping aluminum coatings on Q235 steel substrate

Micro-arc oxidation (MAO) is not applicable to prepare ceramic coatings on the surface of steel directly. In this work, hybrid method of MAO and hot-dipping aluminum (HDA) were employed to fabricate composite ceramic coatings on the surface of Q235 steel. The evolution of MAO coatings, such as growth rate, thickness of the total coatings, ingrown and outgrown coatings, cross section and surface morphologies and phase composition of the ceramic coatings were studied. The results indicate that both the current density and the processing time can affect the total thickness, the growth rate and the ratio of ingrown and outgrown thickness of the ceramic coatings. The total thickness, outgrown thickness and growth rate have maximum values with the processing time prolonged. The time when the maximum value appears decreases and the ingrown dominant turns to outgrown dominant little by little with the current density increasing. The composite coatings obtained by this hybrid method consists of three layers from inside to outside, i.e. Fe-Al alloy layer next to the substrate, aluminum layer between the Fe-Al layer and the ceramic coatings which is as the top exterior layer. Metallurgical bonding was observed between every of the two layers. There are many micro-pores and micro-cracks, which act as discharge channels and result of quick and non-uniform cooling of melted sections in the MAO coatings. The phase composition of the ceramic coatings is mainly composed of amorphous phase and crystal Al₂O₃ oxides. The crystal Al₂O₃ phase includes κ-Al₂O₃, θ-Al₂O₃ and β-Al₂O₃. Compared with the others, the β-Al₂O₃ content is the least. The MAO process can be divided into three periods, namely the common anodic oxidation stage, the stable MAO stage and the ceramic coatings destroyed stage. The exterior loose part of the ceramic coatings was destroyed badly in the last period which should be avoided during the MAO process.     

Spectroscopic study on thermal reaction and desorption of sulfur/Rh(1 0 0) induced by oxygen-containing molecules

The surface reaction and desorption of sulfur on Rh(1 0 0) induced by O₂ and H₂O are investigated with X-ray photoelectron spectroscopy (XPS) technique. The Rh(1 0 0) sample covered with atomic sulfur is prepared by means of the exposure to H₂S gas, and subsequently the sample is annealed under O₂ or H₂O atmosphere. The XPS results show that atomic sulfur adsorbed on Rh(1 0 0) reacts with O₂ and desorbs from the surface at 473 K or more. On the other hand, atomic sulfur can not be removed from Rh(1 0 0) surface by H₂O at any temperature.