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Reactive Plasma Spraying of Fine Al2O3/AlN Feedstock Powder

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Abstract

Reactive plasma spraying (RPS) is a promising technology for in situ formation of aluminum nitride (AlN) coatings. Recently, AlN-based coatings were fabricated by RPS of alumina (Al2O3) powder in N2/H2 thermal plasma. This study investigated the feasibility of RPS of a fine Al2O3/AlN mixture and the influence of the plasma gases (N2, H2) on the nitriding conversion, and coating microstructure and properties. Thick AlN/Al2O3 coatings with high nitride content were successfully fabricated. The coatings consist of h-AlN, c-AlN, Al5O6N, γ-Al2O3, and a small amount of α-Al2O3. Use of fine particles enhanced the nitriding conversion and the melting tendency by increasing the surface area. Furthermore, the AlN additive improved the AlN content in the coatings. Increasing the N2 gas flow rate improved the nitride content and complete crystal growth to the h-AlN phase, and enhanced the coating thickness. On the other hand, though the H2 gas is required for plasma nitriding of the Al2O3 particles, increasing its flow rate decreased the nitride content and the coating thickness. Remarkable influence of the plasma gases on the coating composition, microstructure, and properties was observed during RPS of the fine particles.

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Acknowledgments

This research was support by grants-in-aid for JSPS fellows (232575) of the Japan Society for the Promotion of Science (JSPS).

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Authors and Affiliations

  1. Toyohashi University of Technology, 1-1, Tempaku-cho, Toyohashi, 441-8580, Japan

    Mohammed Shahien, Motohiro Yamada, Toshiaki Yasui & Masahiro Fukumoto

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  1. Mohammed Shahien
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  2. Motohiro Yamada
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  3. Toshiaki Yasui
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  4. Masahiro Fukumoto
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Correspondence to Mohammed Shahien.

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Shahien, M., Yamada, M., Yasui, T. et al. Reactive Plasma Spraying of Fine Al2O3/AlN Feedstock Powder. J Therm Spray Tech 22, 1283–1293 (2013). https://doi.org/10.1007/s11666-013-9992-x

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  • DOI: https://doi.org/10.1007/s11666-013-9992-x

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