Plasma Spraying of Dense Ceramic Coating with Fully Bonded Lamellae Through Materials Design Based on the Critical Bonding Temperature Concept
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It is usually difficult to deposit a dense ceramic coating with fully bonded splats by plasma spraying at a room temperature. Following the recent research progress on the splat interface bonding formation, it was found that there is a well-defined relationship between the critical bonding temperature and the melting point of spray material. Thus, it can be proposed to control the lamellar bonding through the deposition temperature. In this study, to examine the feasibility of the bonding formation theory, a novel approach to the development of ceramic coating with dense microstructure by plasma spraying through materials design with a low melting point is proposed. Potassium titanate K2Ti6O13 was selected as a typical ceramic material of a relatively low melting point for plasma spraying deposition of dense coating with well-bonded splats. Experiment was conducted by using K2Ti6O13 for both splat and coating deposition. Results show that the splat is fully bonded with a ceramic substrate at room temperature, and the K2Ti6O13 coating presents a dense microstructure and a fracture surface morphology similar to sintered bulk ceramic, revealing excellent interlamellar bonding formation. Moreover, both the hardness test and erosion test at 90° further confirmed the formation of the isotropic ceramic coating with fully bonded lamellae.
Keywordsdense ceramic coatings erosion behavior K2Ti6O13 lamellae bonding plasma spraying
The present project is financially supported by National Science Foundation (No. 51171144) and the National Basic Research Program of China (No. 2012CB625104).
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