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.     

Microstructure, bonding strength and thermal shock resistance of ceramic coatings on steels prepared by plasma electrolytic oxidation

Ceramic coatings were successfully prepared on steel by plasma electrolytic oxidation (PEO) in aluminate electrolyte and silicate electrolyte, respectively. The microstructure of the coatings including surface morphology, phase and element composition were studied by scanning electron microscopy (SEM) and X-ray diffraction (XRD), respectively. The bonding strength between the ceramic coating and the substrate was tested using different methods including tensile tests and shearing tests. The thermal shock resistance of the coatings was also evaluated. The results indicated that coatings obtained in both electrolytes were porous and coarse. The average diameters of the pores were below 10 μm. PEO coatings obtained in aluminate electrolyte were composed of Fe₃O₄ and FeAl₂O₄, while those obtained in silicate electrolyte were in a noncrystal state. PEO coatings obtained in aluminate electrolyte showed similar change trend of tensile strength and shearing strength with increasing treating time, namely, a relatively high values with middle time treating and low value with short and long time treating. The best coating was the samples treated with 30 min, whose tensile strength was 20.6 MPa and shearing strength was 16 MPa. The tensile strength and shearing strength of coatings obtained in silicate electrolyte were not strongly influenced by the treating time, the values of which were range in 14 ± 2 MPa and 11 ± 2 MPa, respectively. Coatings obtained in both electrolytes showed the best thermal shock resistance with middle time treating. Coatings obtained in silicate electrolyte show a little better thermal shock resistance than those obtained in aluminate electrolyte.     

Microstructure and infrared emissivity property of coating containing TiO2 formed on titanium alloy by microarc oxidation

Ceramic coatings containing TiO₂ were formed on Ti6Al2Zr1Mo1V alloy surface by microarc oxidation (MAO) method. The microstructure, phase and chemical composition of the coatings were analyzed by SEM, XRD and EDS techniques. The coating mainly consists of rutile TiO₂ and a small amount of anatase TiO₂. The infrared emissivity values of coated and uncoated titanium samples when exposed to 700 °C were tested. It was found that the coating exhibits a higher infrared emissivity value (about 0.9) in the wavelength range of 8–14 μm than that of the uncoated titanium alloy, although which shows a slight increase from 0.1 to 0.3 with increasing exposure time at 700 °C. The relatively high infrared emissivity value of the MAO coating is possibly attributed to the photon emission from the as formed TiO₂ phase.     

Effect of spraying power on microstructure and bonding strength of MoSi2-based coatings prepared by supersonic plasma spraying

MoSi₂-based oxidation protective coatings for SiC-coated carbon/carbon composites were prepared using a supersonic plasma spraying at the power of 40 kW, 45 kW, 50 kW and 55 kW, respectively. Effect of spraying power on the microstructure and bonding strength of MoSi₂-based coatings was studied. The results show that coatings become more and more compact and the bonding strength increases when the spraying power increases from 40 kW to 50 kW. At the power of 50 kW, the coatings were dense and the bonding strength reached a maximum value of 14.5 MPa. As the spraying power is of sufficient magnitude, many cracks and pores reappaer in coatings and the bonding strength between coating and substrate also decreases.     

Influence of treating frequency on microstructure and properties of Al2O3 coating on 304 stainless steel by cathodic plasma electrolytic deposition

Alumina ceramic coatings were fabricated on 304 stainless steel by cathodic plasma electrolytic deposition (CPED). Influence of treating frequency of the power supply on the microstructure and properties of the coatings were studied. The results indicated that coatings obtained at various frequencies on 304 stainless steels were all composed of α-Al₂O₃ and γ-Al₂O₃, and α-Al₂O₃ was the dominant phase. The contents of α-Al₂O₃ decreased gradually in a very small rate with increasing the frequency and γ-Al₂O₃ gradually increased. The surface of alumina ceramic coating was porous. With increasing the frequency, the coating surface gradually became less rough and more compact, resulting in low surface roughness. The bonding strength of Al₂O₃ coating was higher than 22 MPa and was not strongly affected by treating frequency. With increasing the frequency, the alumina coated steels showed better and gradually increasing corrosion resistance than the uncoated one in 3.5% NaCl solution. The coating steel with desirable corrosion resistance was obtained at 800 Hz whose corrosion current potential and corrosion density were −0.237 V and 7.367 × 10⁻⁸ A/cm², respectively.     

Effect of NaAlO2 concentrations on microstructure and corrosion resistance of Al2O3/ZrO2 coatings formed on zirconium by micro-arc oxidation

In this study, Al₂O₃/ZrO₂ composite coatings were prepared on Zr substrates by micro-arc oxidation (MAO) in the NaAlO₂-containing electrolytes, and the effect of NaAlO₂ concentration on the microstructure, bond strength, microhardness and corrosion resistance of coatings was systematically investigated. The study reveals that the adequate NaAlO₂ in the electrolyte (>0.2 M) is essential to the formation of needle-like α-Al₂O₃ in the coatings, and the amount of α-Al₂O₃ rises with the increase of the NaAlO₂ concentration. m-ZrO₂ and t-ZrO₂ are present in all of the coatings, but their relative amount largely depends on the amount of Al₂O₃. It is also found that as the NaAlO₂ concentration increases from 0.2 to 0.3 M, the coating becomes denser and thicker, and its bond strength, maximum microhardness and corrosion resistance increases as well. The coating formed at 0.3 M NaAlO₂ demonstrates the highest bond strength of 52 MPa, the maximum microhardness of 1600 Hv_0.2N and the superior corrosion resistance. However, the overhigh concentration of NaAlO₂ (0.35 M) is found harmful to the coating's microstructure and properties.     

Dependence of infrared radiation on microstructure of polymer derived ceramic coating on steel

High infrared emissivity ceramic coatings were prepared on 304 steel by pyrolyzing reactions with poly(hydridomethylsiloxane) (PHMS) and Al/Cr₂O₃ based mixing powders. The effects of pyrolysis temperature, testing temperature and surface roughness on infrared radiation of polymer derived ceramic coating were systematically investigated. The results indicated that the coating pyrolyzed at 800 °C exhibited a slightly higher infrared emissivity value than that of the coating pyrolyzed at 600 °C, which was attributed to the enhancing photon emission caused by the complete conversion of Al to Al₂O₃ and PHMS pyrolysis into SiO₂, together with the introduction of Cr₂O₃ based mixing powders. The emissivity value in 3–8 μm waveband of the coating was lower about 0.03 at 600 °C compared with 800 °C testing temperature, while the emissivity value was almost the same in 8–20 μm waveband. The high surface roughness of the coating led to a slightly increasing emissivity due to the enhancing infrared absorbance.     

Double-ceramic-layer thermal barrier coatings based on La2(Zr0.7Ce0.3)2O7/La2Ce2O7 deposited by electron beam-physical vapor deposition

Double-ceramic-layer (DCL) thermal barrier coatings (TBCs) of La₂(Zr_0.7Ce_0.3)₂O₇ (LZ7C3) and La₂Ce₂O₇ (LC) were deposited by electron beam-physical vapor deposition (EB-PVD). The composition, interdiffusion, surface and cross-sectional morphologies, cyclic oxidation behavior of DCL coating were studied. Energy dispersive spectroscopy and X-ray diffraction analyses indicate that both LZ7C3 and LC coatings are effectively fabricated by a single LZ7C3 ingot with properly controlling the deposition energy. The chemical compatibility of LC coating and thermally grown oxide (TGO) layer is unstable. LaAlO₃ is formed due to the chemical reaction between LC and Al₂O₃ which is the main composition of TGO layer. Additionally, the thermal cycling behavior of DCL coating is influenced by the interdiffusion of Zr and Ce between LZ7C3 and LC coatings. The failure of DCL coating is a result of the sintering of LZ7C3 coating surface, the chemical incompatibility of LC coating and TGO layer and the abnormal oxidation of bond coat. Since no single material that has been studied so far satisfies all the requirements for high temperature applications, DCL coating is an important development direction of TBCs.     

Finite element simulation of stress distribution and development in 8YSZ and double-ceramic-layer La2Zr2O7/8YSZ thermal barrier coatings during thermal shock

In this paper, the thermal stress of the double-ceramic-layer (DCL) La₂Zr₂O₇/8YSZ thermal barrier coatings (TBCs) fabricated by atmospheric plasma spraying (APS) during thermal shock has been calculated. The residual stress of the coating after being sprayed has been regarded as the initial condition of the first thermal cycle. The characteristic of the stress development during the thermal cycle has been discussed, and the influence of the defects on the failure mode during the thermal cycle has also been discussed systematically. Finite element simulation results show that there exist higher radial thermal shock stresses on the ceramic layer surface of these two coatings. There also exist higher thermal stress gradient at the interface between the ceramic layer and the metallic layer. Higher thermal stress in 8YSZ/NiCoCrAlY coating lead to the decrease of thermal shock property as compared to that of LZ/8YSZ/NiCoCrAlY coating. The addition of LZ ceramic layer can increase the insulation temperature, impede the oxygen transferring to the bond coating and can also reduce the thermal stress. Considering from the aspects of thermal insulation ability and the thermal shock resistance ability, DCL type LZ/8YSZ TBCs is a more promising coating material compared with the single-ceramic-layer (SCL) type 8YSZ TBCs for the application.     

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.     

Effect of α-Al2O3 on the properties of cold sprayed Al/α-Al2O3 composite coatings on AZ91D magnesium alloy

Composite coatings using pure Al powder blended with α-Al₂O₃ as feedstock were deposited on AZ91D magnesium alloy substrates by cold spray (CS). The content of α-Al₂O₃ in the feedstock was 25 wt.% and 50 wt.%, respectively. The effects of α-Al₂O₃ on the porosity, microhardness, adhesion and tensile strength of the coatings were studied. Electrochemical tests were carried out in neutral 3.5 wt.% NaCl solution to evaluate the effect of α-Al₂O₃ on the corrosion behavior of the coatings. The results showed that the composite coatings possessed lower porosity, higher adhesion strength and tensile strength than cold sprayed pure Al coating. The corrosion current densities of the composite coatings were similar to that of the pure Al coating and much higher than that of bare AZ91D magnesium alloy.     

Preparation and characteristics of three-layer YSZ-(YSZ/Al2O3)-YSZ TBCs

Novel three-layer YSZ-(YSZ/Al₂O₃)-YSZ (6 wt.% Y₂O₃ partially stabilized ZrO₂) thermal barrier coatings (TBCs) were successfully prepared on Ni-based superalloy substrate using composite sol-gel and pressure filtration microwave sintering (PFMS) techniques. The coatings were evaluated for the cyclic oxidation resistance, thermal barrier effect and the presences of phases and microstructures. FE-SEM results indicate that the coatings were dense and crack-free. The coatings maintained their structural integrity when they were exposed at 1100 for 100 h. They exhibited superior oxidation resistance, spallation resistance and thermal insulation property compared with single-layer YSZ coatings. Moreover, the detailed mechanisms were discussed in order to understand the improved performance of the three-layer TBCs.     

High performance nanostructured ZrO2 based thermal barrier coatings deposited by high efficiency supersonic plasma spraying

In this paper, the nanostructured zirconia (ZrO₂) based thermal barrier coatings (TBCs) deposited by high efficiency supersonic atmospheric plasma spraying (SAPS), were described. The phase composition, microstructure, thermal conductivity and thermal shock resistance of as-sprayed coating were studied. The results revealed that the as-sprayed coating was composed of tetragonal zirconia and consisted of some unmelted nanoparticles (30-50 nm) and nanograins (60-110 nm), and the latter was the main microstructure of the coating. The nanograins and homogeneously distributed micro-cracks of coating resulted in not only low thermal conductivity, but also high thermal cycling lives. Besides, the failure process of coating during thermal cycles was also investigated in the present work.     

Excellent stability of plasma-sprayed bioactive Ca3ZrSi2O9 ceramic coating on Ti-6Al-4V

In this work, novel zirconium incorporated Ca-Si based ceramic powder Ca₃ZrSi₂O₉ was synthesized. The aim of this study was to fabricate Ca₃ZrSi₂O₉ coating onto Ti-6Al-4V substrate using atmospheric plasma-spraying technology and to evaluate its potential applications in the fields of orthopedics and dentistry. The phase composition, surface morphologies of the coating were examined by XRD and SEM, which revealed that the Ca₃ZrSi₂O₉ coating was composed of grains around 100 nm and amorphous phases. The bonding strength between the coating and the substrate was 28 ± 4 MPa, which is higher than that of traditional HA coating. The dissolution rate of the coating was assessed by monitoring the ions release and mass loss after immersion in the Tris-HCl buffer solution. The in vitro bioactivity of the coating was determined by observing the formation of apatite on its surface in simulated body fluids. It was found that the Ca₃ZrSi₂O₉ coating possessed both excellent chemical stability and good apatite-formation ability, suggesting its potential use as bone implants.     

Successive phase transitions in tetra(isopropylamine)decachlorotricadmate (II) [(CH3)2CH NH3]4Cd3Cl10] crystal - Dielectric and dilatometric studies

Single crystal of a new [(CH₃)₂CHNH₃]₄Cd₃Cl₁₀ compound was grown and its properties have been characterized by dielectric and dilatometric investigations. Dielectric measurement evidenced the phase transitions at T₁ = 352.8 K, T₂ = 293.5 K and T₃ = 261.5 K on cooling run. Dilatometric measurement of thermal expansion showed clearly two successive phase transitions at T₁ and at T₂. No temperature hysteresis was observed for phase transitions at T₁ and T₂. Large temperature hysteresis was observed at T₃ in dielectric studies. Transitions at T₁ and T₃ are classified as a first order and at T₂ as a continuous one. Anomalies of electric permittivity and expansion connected with the transitions are observed at practically the same temperatures and close to those observed earlier in DSC (Differential Scanning Calorimetry) studies. Results of dilatometric studies were applied to estimate critical coefficient β for continuous phase transition at T₁ which is equal to 0.40 ± 0.01.     

Effect of thermal annealing on the ac impedance of Co/Al2O3/Co/Al2O3/Co double-barrier MTJs

Double-barrier magnetic tunnel junctions (DBMTJs) were prepared from Co(75 nm)/Al₂O₃(2.3 nm)/Co(5 nm)/Al₂O₃(2.3 nm)/Co(50 nm) sputtering pentalayer films. The ac electrical properties of as-deposited DBMTJs and those annealed in a vacuum at 100–350 °C for 30 min were then investigated using a complex impedance spectroscopic technique. The ac impedance responses as a function of annealing temperature were further analyzed based on Maxwell's layered dielectric barrier and Maxwell–Wagner capacitor models after considering the DBMTJs as having double-capacitor-type structures. The effect of thermal annealing on the ac transport behavior of the DBMTJs was interpreted by examining the equivalent electric circuits fitted to Nyquist plots of each different sample. The effects were found to be due to changes in the structural characteristics in both bulk and interface morphologies of Co and Al₂O₃ layers. The structural morphology determined the different ac transport modes that occurred in the DBMTJs.     

Formation of titania composite coatings on carbon steel by plasma electrolytic oxidation

Titania composite coatings were prepared on carbon steel by plasma electrolytic oxidation in silicate electrolyte and aluminate electrolyte with titania powers doping in the electrolytes. The microstructure of the coatings was characterized by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD). The properties of the coatings including bond strength, thickness, thermal shock resistance and corrosion resistance varying with the quantities of titania powers in the electrolytes were studied. Investigation results revealed that the coating obtained in silicate electrolyte was composed of anatase-TiO₂, rutile-TiO₂ crystal phases and some Fe, Si, P elements; coating obtained in aluminate electrolyte consisted of anatase-TiO₂, Al₂TiO₅ and some Fe, P elements. Coatings obtained in two types of electrolytes show porous and rough surface. With increasing the concentration of titania powers in the electrolytes, the coating surface first became more compact and less porous and then became more porous and coarse. The bond strength and thickness were not strongly affected by concentration of titania powers in electrolytes. The valves were 23 MPa and for 66 μm for coatings obtained in aluminate electrolyte, and 21 MPa and 35 μm for coatings obtained in silicate electrolyte. Coatings obtained in silicate electrolyte showed a little better thermal shock resistance than those obtained in aluminate electrolyte and the best coatings were obtained with middle concentration of titania powers in the electrolytes. All coated samples showed better corrosion resistance than the substrate in 3.5 wt% NaCl solution. The best coatings were also obtained with middle concentration of titania powers doping in both electrolytes whose corrosion current density was decreased by 2 orders of magnitude compared with the substrate.     

Preparation and properties of composite ceramic coating containing Al2O3–ZrO2–Y2O3 on AZ91D magnesium alloy by plasma electrolytic oxidation

A composite ceramic coating containing Al₂O₃–ZrO₂–Y₂O₃ was successfully prepared on AZ91D magnesium alloy by plasma electrolytic oxidation (PEO) technique in an alkaline aluminate electrolyte. The morphology, elemental and phase composition, corrosion behavior and thermal stability of the uncoated and coated samples were studied by environmental scanning electron microscopy (ESEM), energy dispersive X-ray spectrometer (EDS), X-ray diffractometer (XRD), electrochemical corrosion test, high temperature oxidation test and thermal shock test. The results showed that the composite ceramic coating was composed of Al₂O₃, c-ZrO₂, t-ZrO₂, Y₂O₃ and some magnesium compounds, such as MgO, MgF₂ and MgAl₂O₄. After PEO treatment, the corrosion potential of AZ91D alloy was increased and the corrosion current density was significantly reduced. Besides, the coated magnesium alloys also showed excellent high temperature oxidation resistance and thermal shock resistance at 500 °C environment.     

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.     

Optimizing mechanical and thermal expansion properties of carbon/carbon composites by controlling textures

The present study explored the effect of medium texture (MT) content on flexural properties and thermal expansion coefficients (CTE_S) of carbon/carbon (C/C) composites with multilayered pyrolytic carbon. The specimen with 39% MT exhibited maximum flexural strength of 221.55 MPa, increasing by 52% compared with pure high texture. While the flexural strength decreased when the MT content exceeded 39%. The excellent strength can be attributed to crack deflection between multilayered texture and the strong interface bonding between fibers and matrix. Moreover, the four specimens expressed a similar trend of CTE_S in the direction of XY and Z. In the direction of XY, the specimen with 39% MT had the lowest CTE_S from 800 °C to 2100 °C. Therefore, the C/C composites with 39% MT have the best mechanical and thermal expansion properties, which means that the properties of C/C composites can be optimized by controlling the texture.