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Understanding the Formation of Limited Interlamellar Bonding in Plasma Sprayed Ceramic Coatings Based on the Concept of Intrinsic Bonding Temperature

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Abstract

Interlamellar bonding is an important factor controlling the mechanical, thermal and electrical properties of plasma sprayed ceramic coatings. In order to understand the formation of limited interlamellar bonding, a theoretical model is proposed based on the concept of the intrinsic bonding temperature. The numerical simulation of the interface temperature between a molten splat and underlying splats was performed for splats with uniform and non-uniform thickness, in order to reveal the conditions for the interlamellar bonding formation. The interlamellar bonding ratio was theoretically estimated based on the bonding forming conditions. The features of interlamellar bonding revealed by the simulation agree well with the experimental observations. The bonding ratio of plasma sprayed coatings is significantly influenced by the distribution of splat thickness. According to the distribution of Al2O3 splat thickness in the coating, the theoretical estimation of bonding ratio yielded a value of 0.41 for the plasma sprayed Al2O3 coating at the ambient atmosphere conditions, which is reasonably consistent with the observation value. Therefore, the limited interlamellar bonding can be reasonably explained based on the sufficient condition that the maximum interface temperature between a molten splat and underlying splats is larger than the intrinsic bonding temperature.

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Acknowledgments

The present project is financially supported by the National Basic Research Program of China (Grant No. 2012CB625100) and National Natural Science Foundation of China (Grant No. 51171144).

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  1. State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi’an Jiaotong University, Xi’an, 710049, Shaanxi Province, People’s Republic of China

    Shu-Wei Yao, Jia-Jia Tian, Chang-Jiu Li, Guan-Jun Yang & Cheng-Xin Li

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Correspondence to Chang-Jiu Li.

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Yao, SW., Tian, JJ., Li, CJ. et al. Understanding the Formation of Limited Interlamellar Bonding in Plasma Sprayed Ceramic Coatings Based on the Concept of Intrinsic Bonding Temperature. J Therm Spray Tech 25, 1617–1630 (2016). https://doi.org/10.1007/s11666-016-0464-y

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