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Epitaxial Growth and Cracking Mechanisms of Thermally Sprayed Ceramic Splats

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Abstract

In the present study, the epitaxial growth and cracking mechanisms of thermally sprayed ceramic splats were explored. We report, for the first time, the epitaxial growth of various splat/substrate combinations at low substrate temperatures (100 °C) and large lattice mismatch (− 11.26%). Our results suggest that thermal spray deposition was essentially a liquid-phase epitaxy, readily forming chemical bonding. The interface temperature was also estimated. The results convincingly demonstrated that atoms only need to diffuse and rearrange over a sufficiently short range during extremely rapid solidification. Concurrently, severe cracking occurred in the epitaxial splat/substrate systems, which indicated high tensile stress was produced during splat deposition. The origin of the tensile stress was attributed to the strong constraint of the locally heated substrate by its cold surroundings.

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Acknowledgments

The present project is supported by National Basic Research Program (Nos. 2013CB035701), the Fundamental Research Funds for the Central Universities, and the National Program for Support of Top-notch Young Professionals.

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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, People’s Republic of China

    Lin Chen & Guan-jun Yang

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Correspondence to Guan-jun Yang.

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Chen, L., Yang, Gj. Epitaxial Growth and Cracking Mechanisms of Thermally Sprayed Ceramic Splats. J Therm Spray Tech 27, 255–268 (2018). https://doi.org/10.1007/s11666-018-0692-4

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