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Fabrication and Characterization of Amorphous Alumina-Yttria-Stabilized Zirconia Coatings by Air Plasma Spraying

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Abstract

Almost fully amorphous coatings of near-eutectic alumina-yttria-stabilized zirconia (Al2O3-YSZ) were prepared by air plasma spraying using Al2O3 and 8 mol.% YSZ crystalline-mixed powders. The coatings consist of mostly an amorphous phase with a small amount of nanocrystals. Various characterization techniques were used to understand coating formation and the origins of the different phases within the coatings. The formation of the mostly amorphous structure is attributed to the high glass-forming ability of Al2O3-YSZ and the appropriate plasma spraying conditions. A small number of nanocrystals are produced during crystallization of the incoming molten droplets or by recrystallization of the solidified splats by accumulated heat. Scanning electron microscopy shows that the coatings have a dense, layered structure with low porosity, and bright-field transmission electron microscopy images indicate sharp interface rather than grit-blasted wavy surface between splats and substrates in the coatings. The as-sprayed amorphous coatings crystallized at around 920 °C and micro-hardness of the as-sprayed amorphous coatings was 8.12 GPa.

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Acknowledgment

Financial support from the research project fund of International Science & Technology Cooperation Project of China (2013DFG52290) and Science & Technology Innovation Key Project of Shanghai Institute of Ceramics (Y37ZC4141G) are gratefully acknowledged.

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Authors and Affiliations

  1. The State Key Lab of High Performance Ceramics and Superfine Microstructure, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai, 200050, China

    Xuemei Song & Yi Zeng

  2. VTT Technical Research Centre of Finland, Espoo, 02044, Finland

    Tomi Suhonen & Tommi Varis

  3. Key Laboratory of Inorganic Coating Materials, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai, 200050, China

    Liping Huang & Xuebin Zheng

Authors
  1. Xuemei Song
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  2. Tomi Suhonen
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  3. Tommi Varis
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  6. Yi Zeng
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Correspondence to Yi Zeng.

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Song, X., Suhonen, T., Varis, T. et al. Fabrication and Characterization of Amorphous Alumina-Yttria-Stabilized Zirconia Coatings by Air Plasma Spraying. J Therm Spray Tech 23, 1302–1311 (2014). https://doi.org/10.1007/s11666-014-0124-z

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  • DOI: https://doi.org/10.1007/s11666-014-0124-z

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