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Development of ZrB2-SiC Plasma-Sprayed Ceramic Coating for Thermo-chemical Protection in Hypersonic Vehicles

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Abstract

The aim of this research is to explore the potential of ZrB2-SiC-based ceramic coatings as a protective layer for Inconel 718 substrates. The study focuses on the use of shrouded plasma spraying technology to deposit the coating and investigates the effect of exposure to molten sulfate-vanadate salts (45% Na2SO4 and 55% V2O5) on its properties. The tribological behavior and corrosion resistance of the coated samples were evaluated, and the results revealed that the ZrB2-SiC coating showed resistance to hot corrosion. Upon exposure to the molten salt mixture, the ZrB2-SiC coating was found to interact with V2O5 and Na2SO4, forming binary oxide phases, such as NaVO3 and SiO2. The formation of the ZrO2 monoclinic phase was observed due to the leaching of B2O3 from the ZrB2-SiC coating. However, the physical properties of ZrB2-SiC were found to prevent the penetration of the molten salt, thus reducing its corrosive effect. Overall, the results indicate that ZrB2-SiC-based ceramic coatings have the potential to offer effective protection to Inconel 718 substrates against hot corrosion in harsh environments.

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Authors and Affiliations

  1. Mechanical Engineering, Delhi Technological University, Delhi, India

    Kalpana Gupta, Qasim Murtaza & N. Yuvraj

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  1. Kalpana Gupta
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  2. Qasim Murtaza
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  3. N. Yuvraj
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Correspondence to Kalpana Gupta.

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Gupta, K., Murtaza, Q. & Yuvraj, N. Development of ZrB2-SiC Plasma-Sprayed Ceramic Coating for Thermo-chemical Protection in Hypersonic Vehicles. J. of Materi Eng and Perform 33, 1401–1410 (2024). https://doi.org/10.1007/s11665-023-08043-9

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