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Effect of Addition of Multimodal YSZ and SiC Powders on the Mechanical Properties of Nanostructured Cr2O3 Plasma-Sprayed Coatings

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Abstract

In this research, the effect of the addition of multimodal yttria-stabilized zirconia (YSZ) and SiC reinforcements on the mechanical properties of Cr2O3 plasma-sprayed coatings was studied. For this purpose, the starting powders were ball milled for 5 h and then mixed and agglomerated, prior to spraying. Cr2O3, Cr2O3-20YSZ (CZ), and Cr2O3-20YSZ-10SiC (CZS) coatings were then deposited onto 304L steel substrates using the atmospheric plasma spray process. Microstructural evaluations of the initial/milled powders and the plasma-sprayed coatings were conducted through x-ray diffraction, field emission scanning electron microscopy (FESEM) equipped with energy-dispersive x-ray spectroscopy and porosity measurements. The microscopic images indicated that the multimodal milled powders resulted in nanostructured coatings. Mechanical tests including adhesive strength, fracture toughness, and micro-hardness were used to understand the dependence of the properties of coatings and their microstructure. Adding tough YSZ particles to the C coating considerably increased the toughness through the phase transformation-toughening mechanism of tetragonal zirconia while decreasing micro-hardness of the coating; therefore, intrinsically hard SiC particles were added to the CZ coating to deal with the reduced hardness. Moreover, when compared to pure C coating, CZ, and CZS Composite coatings showed comparable bonding strengths and higher porosities.

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Data availability

The authors are willing to firstly publish this research paper through the highly prestigious journal of “Thermal Spray Technology”. Therefore the datasets generated and analyzed during the current study have not already been available in public. However, it can be available from the corresponding author on a reasonable request.

Notes

  1. Standard cubic feet per hour.

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  1. Department of Mining and Metallurgical Engineering, Amirkabir University of Technology, Tehran, Iran

    S. M. Hashemi & N. Parvin

  2. Materials Engineering Research Center, Malek Ashtar University of Technology, Tehran, Iran

    Z. Valefi

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Hashemi, S.M., Parvin, N. & Valefi, Z. Effect of Addition of Multimodal YSZ and SiC Powders on the Mechanical Properties of Nanostructured Cr2O3 Plasma-Sprayed Coatings. J Therm Spray Tech 28, 544–562 (2019). https://doi.org/10.1007/s11666-019-00834-8

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