Skip to main content
SpringerLink
Log in

Thermal Cycling Assessment of Steel-Based Thermal Barrier Coatings for Al Protection

  • Peer Reviewed
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

There is a strong interest from the transportation industry to achieve vehicle weight reduction through the replacement of steel components by aluminum parts. For some applications, aluminum requires protective coatings due to its limited wear and lower temperature resistance compared to steel. The objective of this study was to assess the potential of amorphous-type plasma-sprayed steel coatings and conventional arc-sprayed steel coatings as thermal barrier coatings, mainly through the evaluation of their spalling resistance under thermal cycling. The microstructures of the different coatings were first compared via SEM. The amorphicity of the coatings produced via plasma spraying of specialized alloyed steel and the crystalline phases of the conventional arc-sprayed steel coatings were confirmed through x-ray diffraction. The thermal diffusivity of all coatings produced was measured to be about a third of that of bulk stainless steel. Conventional arc-sprayed steel coatings typically offered better spalling resistance under thermal cycling than steel-based amorphous coatings due probably to their higher initial bond strength. However, the presence of vertical cracks in the steel-based amorphous coatings was found to have a beneficial effect on their thermal cycling resistance. The amorphous plasma-sprayed steel coatings presented indications of recrystallization after their exposure to high temperature.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

References

  1. K. Bobzin, F. Ernst, J. Zwick, T. Schlaefer, D. Cook, K. Nassenstein, A. Schwenk, F. Schreiber, T. Wenz, G. Flores, and M. Hahn, Coating Bores of Light Metal Engine Blockes with a Nanocomposite Material Using the Plasma Transferred Wire Arc Thermal Spray Process, J. Therm. Spray Technol., 2008, 17(3), p 344-351

    Article  Google Scholar 

  2. E. Lugscheider, R. Dicks, K. Kowalsky, D. Cook, K. Nassenstein, and C. Verpoort, A Materials System and Method of Its Application for the Wear Protection of Aluminium Engine Cylinder Bore Surfaces, Thermal Spray 2004: Advances in Technology and Applications, May 10-12, 2004 (Osaka Japan), ASM International, Materials Park 2004

  3. D. Shin, F. Gitzhofer, and C. Moreau, Development of Metal Based Thermal Barrier Coatings (MBTBCs) for Low Heat Rejection Diesel Engines, Thermal Spray 2005: Explore its Surfacing Potential!, E. Lugscheider, Ed., May 2-4, 2005, DVS Deutscher Verband fur Schweiβen, Basel, 2005

  4. W.D. Callister, Materials Science and Engineering: An Introduction, Wiley, New York, 2000

    Google Scholar 

  5. D.R. Clarke and C.G. Levi, Materials Design for the Next Generation Thermal Barrier Coatings, Ann. Rev. Mater. Res., 2003, 33, p 383-417

    Article  Google Scholar 

  6. C. Zhang, L. Liu, K.C. Chan, Q. Chen, and C.Y. Tang, Wear Behavior of HVOF-Sprayed Fe-Based Amorphous Coatings, Intermetallics, 2012, 29, p 80-85

    Article  Google Scholar 

  7. C.Z.Y. Yang, Y. Peng, Y. Yu, and L. Liu, Effects of Crystallization on the Corrosion Resistance of Fe-Based Amorphous Coatings, Corros. Sci., 2012, 59, p 10-19

    Article  Google Scholar 

  8. D. Zois, A. Lekatou, and M. Vardavoulias, Preparation and Characterization of Highly Amorphous HVOF Stainless Steel Coatings, J. Alloys Compd, 2010, 504, p S283-S287

    Article  Google Scholar 

  9. P. Rohan, S. Bouaricha, J.G. Legoux, and C. Moreau, Deposition and Crystallization of Thermally Sprayed Amorphous Metallic Coatings, Thermal Spray 2005: Explore its Surfacing Potential!, E. Lugscheider, Ed., May 2-4, 2005, DVS Deutscher Verband fur Schweiβen, Basel, 2005

  10. D.J. Branagan, W.D. Swank, D.C. Haggard, and J.R. Fincke, Wear-Resistant Amorphous and Nanocomposite Steel Coatings, Metall. Mater. Trans. A, 2001, 32(10), p 2615-2621

    Article  Google Scholar 

  11. F. Otsubo and K. Kishitake, Corrosion Resistance of Fe-16%Cr-30%Mo-(C, B, P) Amorphous Coatings Sprayed by HVOF and PS Processes, Mater. Trans., 2005, 46(1), p 80-83

    Article  Google Scholar 

  12. Z. Zhou, L. Wang, F.C. Wng, H.F. Zhang, Y.B. Liu, and S.H. Xu, Formation and Corrosion Behavior F Fe-Based Amorphous Metallic Coatings by HVOF Thermal Spraying, Surf. Coat. Technol., 2009, 204(5), p 563-570

    Article  Google Scholar 

  13. R.Q. Guo, C. Zhang, Q. Chen, Y. Yang, N. Li, and L. Liu, Study of Structure and Corrosion Resistance of Fe-Based Amorphous Coatings Prepared by HVAF and HVOF, Corros. Sci., 2011, 53(7), p 2351-2356

    Article  Google Scholar 

  14. J. Voyer, Surface Wear Improvement of Al-Alloys by Amorphous Iron-Based Flame-Sprayed Coatings, Mater. Sci. Forum, 2011, 690, p 405-408

    Article  Google Scholar 

  15. S.L. Chawla and R.K. Gupta, Materials Selection for Corrosion Control, ASM international, Materials Park, 1993

    Google Scholar 

  16. T. Hejwowski and A. Weronski, The Effect of Thermal Barrier Coatings on Diesel Engine Performance, Vacuum, 2002, 65(3–4), p 427-432

    Article  Google Scholar 

  17. D. Poirier, E. Irissou, and J. G. Legoux, A Laser Thermal Cycling Rig as a New Method to Characterize the Evolution of Coating Adhesion under Thermal Cycle, Thermal Spray 2012: Air, Land, Water, and the Human Body: Thermal Spray Science and Applications, R.S. Lima, A. Agarwal, M.M. Hyland, Y.-C. Lau, C.-J. Li, A. McDonald, and F.-L. Toma, Ed., May 21-24, 2012, ASM International, Houston, TX, 2012

  18. B.K. Venkanna, Fundamentals of Heat and Mass Transfer, PHI, Learning Private Limited, New Delhi, 2010

    Google Scholar 

  19. C.J. Smithells, Metals Reference Book, Butterworth & Co, Chichester, 1976

    Google Scholar 

Download references

Acknowledgment

The authors would like to thank Dr. Rogerio S. Lima for his instructive comments and advice as well as the team of Prof. Sampath, from Stony Brook University, for the dilatometer measurements. The authors would also like to acknowledge the work of Jean-Claude Tremblay (plasma spraying and thermal cycling), Jimmy Sykes (arc spraying), David de Lagrave (characterisation), Michel Thibodeau (SEM, XRD) and Karine Théberge (SEM, XRD).

Author information

Authors and Affiliations

  1. National Research Council of Canada, 75 de Mortagne Blvd., Boucherville, QC, J4B 6Y4, Canada

    Dominique Poirier, Jean-Michel Lamarre & Jean-Gabriel Legoux

Authors
  1. Dominique Poirier
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jean-Michel Lamarre
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jean-Gabriel Legoux
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Dominique Poirier.

Additional information

This article is an invited paper selected from presentations at the 2014 International Thermal Spray Conference, held May 21-23, 2014, in Barcelona, Spain, and has been expanded from the original presentation.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Poirier, D., Lamarre, JM. & Legoux, JG. Thermal Cycling Assessment of Steel-Based Thermal Barrier Coatings for Al Protection. J Therm Spray Tech 24, 175–184 (2015). https://doi.org/10.1007/s11666-014-0190-2

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-014-0190-2

Keywords

Search

Navigation