Contribution to the analytical characterization of coatings produced by thermal spraying

This paper reports on the use of Auger electron spectroscopy (AES)/ depth profile analysis for the investigation of plasma-sprayed coatings. Prior to spraying the St 37 substrates are heated to 300 °C or 500 °C for ceramic or metallic layers, respectively. Studies of the starting materials and of the interfaces are important if the adhesion mechanism is to be understood. Therefore the initial components—the unheated and heated substrates and the powder particles NiCrAl, Al₂O₃ and ZrO₂-7.25Y₂O₃—are analyzed. Depth profiles obtained from two coatings St 37/NiCrAl and St 37/Al₂O₃ show the influence of plasmaspraying on substrate surfaces and sprayed particles. Plasma-spraying mainly causes a decrease of superficial carbon contamination for both coating layers. In the case of St 37/NiCrAl incorporation of carbon in the sprayed layer is observed. The whole layer is almost completely oxidized except for some areas where substrate and particle material are present. It is assumed that these areas are identical with so-called adherence zones.Dedicated to Professor Günther Tölg on the occasion of his 60th birthday     

AES investigations of plasma sprayed Al2O3 coatings on Ni

Summary The system of plasma sprayed Al₂O₃ on Ni substrates is investigated by means of AES/depth profiling. The influence of two process parameters — preoxidation procedure and spraying temperature — is examined. Rupture between substrate and ceramic layer occurs between a residual — or, in the case of excessive preoxidation, a superfluous — NiO layer on Ni, the thickness of the former depending on preoxidation conditions and the Al₂O₃ layer, the back side of which being partially covered with NiO. The thickness of this NiO layer increases up to about 1 m with the thickness of the initial NiO layer on the substrate, until this layer is about 1.3 m thick, and remains constant thereafter. The same dependence is observed for the width (0.1–1 m range) of the mixed oxide interface between the sprayed Al₂O₃ layer and the NiO layer below. These results represent the chemical contribution to adherence. Contrary to excessive preoxidation, an increase of the spraying temperature from 300°C to 500°C effects broader interfaces.This poster was awarded the First Prize in Poster Section C by the Deutscher Arbeitskreis für Spektroskopie (DASp)     

Improved adhesion of copper on Al2O3

Summary Improved methods for Al₂O₃ metallization by Cu are described. Good adhesion between Cu and Al₂O₃ substrate depends on the formation of chemical bonds between the substrate and the metallic layer. The temperature needed for the formation of a CuAl₂O₄ spinel interface is reduced from 1050°C to 900°C by the addition of various oxides. The adhesion between the CuAl₂O₄ interface and deposited Cu is stronger then the tensile strength of pure Cu. Plasma techniques for the formation of a Cu containing interface are also described. Bombardment of a Cu film with Xe⁺ ions in a rf-glow discharge implants Cu atoms into the substrate to a depth of 5 nm, as determined by SIMS depth profiling. Methods for reduction of the CuAl₂O₄ surface for subsequent metallization are also presented.     

Protective yttria coatings of melting crucible for metallic fuel slugs

As one of the candidate coating materials for a melting crucible, yttrium oxides were deposited on graphite and niobium substrates using slurry and plasma spraying methods. Thermal cycling tests and interaction studies between U–Zr/U–Zr–RE fuel melt and the Y₂O₃ coatings were carried out to evaluate the performance as reusable coatings for a melting crucible. A multi‐layer coating method was also applied to overcome the issue of a thermal expansion mismatch between the coating and substrate. The results showed that the plasma‐sprayed coatings showed a good consolidation after deposition compared to slurry coating. The plasma‐sprayed Y₂O₃ coating on the niobium substrate showed better thermal cycling resistance than those coated on a graphite substrate. The proposed TaC/Y₂O₃ double‐layer coating which was plasma‐sprayed on the niobium substrate showed improved characteristics with no reaction layer formation and no separation from the substrate after the interaction with the U–Zr–RE melt. Copyright © 2014 John Wiley & Sons, Ltd.     

Oriented SrFe12O19 thin films prepared by chemical solution deposition

Thin films of SrFe₁₂O₁₉ (SrM) were prepared from a solution of iron and strontium alkoxides through the chemical solution deposition method on both amorphous (glassy SiO₂), and single crystal substrates (Si(100), Si(111), Ag(111), Al₂O₃(001), MgO(111), MgAl₂O₄(111), SrTiO₃(111)) substrates. The process of crystallization was investigated by means of powder diffraction, atomic force microscopy and scanning electron microscopy. Magnetization measurements, ferromagnetic and nuclear magnetic resonance were used for evaluation of anisotropy in the films. Whilst amorphous substrates enabled growth of randomly oriented SrM phase, use of single crystal substrates resulted in samples with different degree of oriented growth. The most pronounced oriented growth was observed on SrTiO₃(111). A detailed inspection revealed that growth of SrM phase starts through the breakup of initially continuous film into isolated grains with expressive shape anisotropy and hexagonal habit. A continuous film with epitaxial relations to the substrate was produced by repeating recoating and annealing.     

Fabrication and electron transport properties of epitaxial films of electron-doped 12CaO·7Al2O3 and 12SrO·7Al2O3

Epitaxial growth and electron doping of 12CaO·7Al₂O₃ (C12A7) and 12SrO·7Al₂O₃ (S12A7) are reported. The C12A7 films were prepared on Y₃Al₅O₁₂ (YAG) single-crystal substrates by pulsed laser deposition at room temperature and subsequent thermal crystallization. X-ray diffraction patterns revealed the films were grown epitaxially with the orientation relationship of (001)[100] C12A7 || (001)[100] YAG. For S12A7, pseudo-homoepitaxial growth was attained on the C12A7 epitaxial layer. Upon electron doping, metallic conduction was achieved in the C12A7 film and the S12A7/C12A7 double-layered films. Analyses of optical absorption spectra for the S12A7/C12A7 films provided the densities of free electrons in each layer separately. Hall measurements exhibited larger electron mobility in the S12A7/C12A7 film than those in C12A7 and S12A7 films, suggesting free electrons may be accumulated at the S12A7/C12A7 interface due presumably to a discontinuity of the cage conduction bands.     

Interfacial microstructure of cold gas spraying coated Al and Mg alloy substrates

The interface between cold gas sprayed zinc-based coatings and selected light weight alloy substrates (aluminium AA7022 and magnesium AZ91) has been investigated by scanning and transmission electron microscopy in combination with energy-dispersive X-ray spectroscopy. In both cases a non-uniform interfacial zone with a thickness of up to 10 microns is evident. It consists of coating and substrate phases as well as an approximately 1 micron thick, partially whirled layer. For the AA7022 substrate the interfacial layer contains nano and submicron sized crystallites of the binary MgZn₂ phase (η) which are embedded in an aluminium solid solution matrix. In the case of AZ91 substrate two ternary phases, Mg₅Zn₂Al₂ (φ) and Mg₁₁Zn₁₁Al₆ (τ) with particle size smaller than 50 nm are evident. The formation of these phases during spraying cannot be explained by diffusion process only, but a local melting is needed. Consequently, the assumption that the high kinetic energy of cold gas sprayed particles causes an intensive mechanical mixing of coating and substrate material accompanied by a high local temperature rise is proved.     

A simple and effective strategy to synthesize Al2O3-coated LiNi0.8Co0.2O2 cathode materials for lithium ion battery

A facile method has been developed to synthesize Al₂O₃-coated LiNi_0.8Co_0.2O₂ cathode materials. The sample was characterized by X-ray diffraction (XRD), high-resolution transmission electron microscopy (HRTEM) and energy dispersive analysis of X-rays (EDAX). Electrochemical tests show that the cycling stability of LiNi_0.8Co_0.2O₂ at room temperature is effectively improved by Al₂O₃ coating. The differential scanning calorimetry (DSC) and high temperature (60 °C) cycling tests indicate that Al₂O₃ coating can also improve the thermal stability of LiNi_0.8Co_0.2O₂, which is attributed to that the coating layer can protect the LiNi_0.8Co_0.2O₂ particles from reacting with the electrolyte.     

Effect of substrate on phase formation and surface morphology of sol-gel lead-free KNbO3, NaNbO3, and K0.5Na0.5NbO3 thin films

Environmentally acceptable lead-free ferroelectric KNbO₃ (KN) or NaNbO₃ (NN) and K_0.5Na_0.5NbO₃ (KNN) thin films were prepared using a modified sol-gel method by mixing potassium acetate or sodium acetate or both with the Nb-tartrate complex, deposited on the Pt/Al₂O₃ and Pt/SiO₂/Si substrates by a spin-coating method and sintered at 650°C. X-ray diffraction (XRD) analysis indicated that the NN and KNN films on the Pt/SiO₂/Si substrate possessed a single perovskite phase, while NN and KNN films on the Pt/Al₂O₃ substrate contained a small amount of secondary pyrochlore phase, as did KN films on both substrates. Scanning electron microscopic (SEM) and atomic force microscopic (AFM) analyses confirmed that roughness R _q of the thin KNN/Pt/SiO₂/Si film (?? 7.4 nm) was significantly lower than that of the KNN/Pt/Al₂O₃ film (?? 15 nm). The heterogeneous microstructure composed of small spherical and larger needle-like or cuboidal particles were observed in the KN and NN films on both substrates. The homogeneous microstructure of the KNN thin film on the Pt/SiO₂/Si substrate was smoother and contained finer spherical particles (?? 50 nm) than on Pt/Al₂O₃ substrates (?? 100 nm). The effect of different substrates on the surface morphology of thin films was confirmed.     

Determination of diffusion induced concentration profiles in Cr2O3 films on ceramic Al2O3 by Auger sputter depth profiling

Annealing induced interface and bulk effects in thin Cr₂O₃ films on aluminum oxide have been studied. The investigated samples have been prepared by reactive r.f. magnetron sputter deposition of Cr₂O₃ on ceramic Al₂O₃ substrates. Annealing at temperatures up to 1250° C have been carried out in situ under ultra high vacuum. Temperature induced compositional changes have been subsequently determined by AES sputter depth profiling without breaking the vacuum. The non-conducting substrates and the overlap of the Cr-(LMM)- and O-(KLL)-Auger peaks required special analysis parameters and spectra interpretation to obtain the concentration depth profiles of the different elements (Al, O, Cr).     

Preparation, morphology and properties of nano-sized Al2O3/polyimide hybrid films

Nano-sized Al₂O₃/polyimide (PI) hybrid films based on 4,4′-oxydianiline (ODA) and pyromellitic dianhydride (PMDA) were prepared by incorporation with different content of nano-sized Al₂O₃ via in situ polymerization. The TEM and SEM micrographs indicated that the Al₂O₃ particles were homogenously dispersed in the polyimide matrix by means of the ultrasonic treatment and the addition of coupling agent. The mechanical properties and thermal stability of the pure PI film can be improved by adequate addition of Al₂O₃. The PI hybrid film was strengthened and toughened simultaneously by the introduction of the well-dispersed Al₂O₃ particles. The PI hybrid films showed improved electrical aging performance as compared with pure PI film. Especially, the PI hybrid films with 10 wt.% of Al₂O₃ content exhibited obviously enhanced electrical aging performance with the time to failure of 3.4 times longer than that of pure PI film. The improved electrical aging performance of the hybrid film was attributed to the nano-sized Al₂O₃ particles highly dispersed in the hybrid film, which confirmed by the investigation of the morphology and the surface composition of PI hybrid film before and after electrical aging.     

Effect of inert components (Y2O3, Al2O3, and Ga2O3) on the chemistimulating effect of the Sb2O3 activator of GaAs thermal oxidation

Chemistimilated thermal oxidation of gallium arsenide was studied using Sb₂O₃ activator oxide in compositions with Ga₂O₃, Al₂O₃, and Y₂O₃ inert components. For Sb₂O₃-Y₂O₃ compositions, the thickness of the resulting oxide layer on GaAs was found to be a linear function of composition over the enter range of the compositions. For antimony oxide compositions with Ga₂O₃ and Al₂O₃ inert components, nonadditivities were observed near the component ordinates. For the Sb₂O₃-Ga₂O₃ system, the chemistimulating efficiency noticeably weakened at low concentrations of the inert component. The linear trend observed for this system within 0–60 mol % Sb₂O₃ is additively determined by the oxide layer thickness on GaAs in the presence of Sb₂O₃ and in the absence of activator. In the presence of inert Al₂O₃, the chemistimulating effect was enhanced near the Al₂O₃ ordinate and the resulting function was nonadditive with respect to the thicknesses reached in the presence of the individual components.     

Characterization of metallic layer composites by means of AES/depth profile analysis

The adherence mechanism of arc sprayed Ni layers on structure steel St37 is investigated. AES depth profiles are obtained on single Ni particles still adhering to the substrate after the Ni layer has been separated from it. A comparison of interface shapes and results of adherence measurements reveals Fe-Ni layered structures for the best adhering layers, whereas less adhering layers are characterized by narrower interfaces caused by diffusion. Areas with no adherence are covered with oxidic layers.     

Sub-nanometer-thick Al2O3 Overcoat Remarkably Enhancing Thermal Stability of Supported Gold Catalysts

Supported gold nanoparticle catalysts show extraordinarily high activity in many reactions. While the relative poor thermal stability of Au nanoparticles against sintering at elevated temperatures severely limits their practical applications. Here atomic layer deposition (ALD) of TiO₂ and Al₂O₃ was performed to deposit an Au/TiO₂ catalyst with precise thickness con-trol, and the thermal stability was investigated. We surprisingly found that sub-nanometer-thick Al₂O₃ overcoat can su ciently inhibit the aggregation of Au particles up to 600 C in oxygen. On the other hand, the enhancement of Au nanoparticle stability by TiO₂ overcoat is very limited. Di use reffectance infrared Fourier transform spectroscopy (DRIFTS) of CO chemisorption and X-ray photoelectron spectroscopy measurements both con rmed the ALD overcoat on Au particles surface and suggested that the presence of TiO₂ and Al₂O₃ ALD overcoat on Au nanoparticles does not considerably change the electronic properties of Au nanoparticles. The catalytic activities of the Al₂O₃ overcoated Au/TiO₂ catalysts in CO oxidation increased as increasing calcination temperature, which suggests that the embed-ded Au nanoparticles become more accessible for catalytic function after high temperature treatment, consistent with our DRIFTS CO chemisorption results.     

Formation of endogenous MgO and MgAl2O4 particles and their possibility of acting as substrate for heterogeneous nucleation of aluminum grains

Aluminum containing 4 wt.% magnesium was oxidized at a temperature for different oxidation times and analyzed by high‐resolution electron microscopy. A thin oxidized layer of about 5 µm, which is composed of MgO, forms at short oxidation time and gradually increases. High‐resolution microstructures reveal that the oxidized layers are porous regardless of oxidation time. After extended oxidation time, discrete MgAl₂O₄ particles formed as a result of the reaction of initially formed MgO, liquid aluminum, and oxygen introduced from air through the porous MgO. Furthermore, it is clear by high‐resolution lattice images that MgAl₂O₄ particles are covered with thin Al₂O₃, whereas MgO is bonded intimately to aluminum. Therefore, MgAl₂O₄ particles that form naturally during oxidation are difficult to act as a direct substrate for nucleation of aluminum grains because of the coverage of Al₂O₃. In contrast, MgO shows the possibility of acting as a substrate for the aluminum nucleation. The formation mechanism of MgO and MgAl₂O₄ and their possibility of acting as substrates for nucleation of aluminum grains suggest that atomic level bonding and mismatches of nucleant/nucleus metal should be considered for correct evaluation of the possibility of heterogeneous nucleation of metallic matrix on a potent nucleant. © 2015 The Authors. Surface and Interface Analysis Published by John Wiley & Sons, Ltd.     

Selective Catalytic Reduction of NO with Propene over Au/Fe2O3/Al2O3 Catalysts

A series of Au/Fe₂O₃/Al₂O₃ catalysts were prepared by the homogeneous deposition-precipitation method. The catalytic activity of the catalyst samples for selective catalytic reduction of NO by propene under oxygen-rich atmosphere was evaluated. The results showed that 2%Au/10%Fe₂O₃/Al₂O₃ exhibited good low-temperature activity. The maximum of NO conversion reached 43% at 300 °C, while it was only 21% over the 2%Au/Al₂O₃ catalyst at the same temperature. The addition of 2% steam to the feed gas had little effect on the catalytic activity. X-ray diffraction results indicated that both Au and Fe₂O₃ particles were highly dispersed over Al₂O₃. H₂-temperature-programmed reduction results indicated that there was strong interaction between Au and Fe₂O₃, which made the reduction of Fe₂O₃ easy. The synergistic effect between Au and Fe₂O₃ was probably responsible for the good catalytic performance of the Au/Fe₂O₃/Al₂O₃ catalyst at low temperature.     

乙烷氧化脱氢用Ni/Al2O3催化剂中活性镍物种前驱体（英文）

Ni/Al2O3 catalysts for oxidative dehydrogenation(ODH) of ethane were prepared by impregnation of Al2O3 with nickel acetate or nickel nitrate,and by mechanical mixing of NiO and Al2O3.The Ni-based catalysts were characterized by N2 adsorption-desorption,X-ray diffraction,diffuse reflectance UV-visible diffuse reflectance spectroscopy,and temperature-programmed reduction of hydrogen.The results showed that formation of crystalline NiO particles with a size of < 8 nm and/or non-stoichiometric NiO species in the Ni/Al2O3 catalysts led to more active species in ODH of ethane under the investigated reaction conditions.In contrast,tetrahedral Ni species present in the catalysts led to higher selectivity for ethene.Formation of large crystalline NiO particles(22-32 nm) over Ni/Al2O3 catalysts decreased the selectivity for ethene.     

Fabrication,morphology and mechanical properties of Al2O3–Al graded coatings on China low activation martensitic steel substrates

Al₂O₃, Al₂O₃/Al and Al₂O₃–Al graded coatings were fabricated on China low activation martensitic steel and silicon substrates by RF magnetron sputtering. The coating composition and cross‐section morphologies were investigated using X‐ray photoelectron spectroscopy, Auger electron spectroscopy and field‐emission scanning electron microscopy. The mechanical properties of the coatings were studied using nanoindentation, wafer‐curvature measurements and microscratch tests. The results show that usable Al₂O₃–Al graded coatings could be fabricated. With a more continuous compositional gradient, the interface zone was more compact. The hardness and elastic modulus of Al₂O₃–Al graded coatings were less than those of Al₂O₃ coatings, but greater than those of Al₂O₃/Al coatings. After annealing at 773 K for 3 h, the hardness of Al₂O₃–Al graded coating showed a small increase. The residual stresses in Al₂O₃–Al graded coatings declined to about 0.3 GPa, compared with the 6.6 GPa for Al₂O₃ coating. The adhesion of Al₂O₃ was improved by deposition of Al or Al compositional gradient oxide layers. Copyright © 2011 John Wiley & Sons, Ltd.     

Two-stage catalytic system of Sn/Al2O3 and Pt/Al2O3for NO reduction by propene in lean conditions

The Pt/Al₂O₃, Sn/Al₂O₃catalysts were prepared by the single sol-gel method. The two-stage Sn/Al₂O₃and Pt/Al₂O₃catalyst in series for NO reduction with propene were investigated. The coexistance of water vapor enhanced the activity at medium temperature of 300-400^oC, and the NO conversion was above 50% at 225 to 500^oC even in the presence of water vapor and SO₂. This revised version was published online in August 2006 with corrections to the Cover Date.     

Study of the cobalt diffusion in CVD-layers by scanning Auger microscopy (SAM)

Summary Multilayers of TiC/Al₂O₃/TiC were deposited by CVD (Chemical Vapor Deposition) on pure cobalt, cemented carbides (WC-Co) and Al₂O₃ substrates. By a low angle cut produced with a ball cratering technique, depth profile measurements were determined by SAM.In the case of the cobalt substrate, the cobalt concentration in the first TiC layer was greater than 10 at %. For the cemented carbide substrate, an enrichment at both interfaces of the first TiC layers was clearly detected. This occurred by diffusion of Co during the cleaning of the hot (1050 ° C) CVD reactor with hydrogen while no CVD deposition occurred. A thin Al₂O₃ layer (0.5 m) proved to be a very efficient diffusion barrier for cobalt.The cobalt diffusing from the substrate acted as accelerator and grain refining agent for the TiC CVD deposition.

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Untersuchung der Kobaltdiffusion in CVD-Schichten mit Scanning Auger Mikroskopie (SAM)