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Study on the Formation of (Co,Ni)O Solid Solution and Metallic Ni Phases During Suspension Plasma Spraying of CoO and NiO Powders

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Abstract

SPS-sprayed (Co,Ni)O coating was investigated as a potential material for inert anode applications in Al production. In-flight particles were collected in water and splats formed on heated smooth metal substrates were captured to gain further insight into the melting and mixing of NiO and CoO powders during spraying. SEM, EDS, and x-ray diffraction analyses contributed to understanding the formation of different crystalline phases within the as-sprayed coatings. It was found that the intermixing of NiO and CoO to form (Co,Ni)O solid solution mainly occurs on the substrate surface, rather than in-flight, while keeping the substrate temperature high. The metallic nickel phase could be formed in the coatings in addition to the (Co,Ni)O solid solution phase. Accordingly, this study discussed in detail the possible causes for the formation of metallic Ni during spraying.

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Acknowledgments

The authors thank the Natural Sciences and Engineering Research Council of Canada (NSERC) through the Strategic program (STPGP/494283-2016), Prima Québec (Grant R13-13-001), Metal7 and Kingston Process Metallurgy for supporting this work. Vahid Jalilvand acknowledges a doctoral research scholarship from Fonds de Recherche du Québec-Nature et Technologies (FRQNT). Saeed Mohammadkhani also acknowledges the support of the UNESCO Chair Materials for Energy Conversion, Saving and Storage (MATECSS) Excellence Scholarship.

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Authors and Affiliations

  1. Department of Mechanical, Industrial and Aerospace Engineering, Concordia University, 1455 de Maisonneuve Blvd. W, Montreal, QC, H3G 1M8, Canada

    Vahid Jalilvand, Fadhel Ben Ettouil & Christian Moreau

  2. INRS-Énergie Matériaux Télécommunications, 1650 Lionel Boulet Blvd, Varennes, QC, J3X 1S2, Canada

    Saeed Mohammadkhani, Lionel Roué & Daniel Guay

  3. Department of Mechanical and Industrial Engineering, University of Toronto, 5 King’s College Road, Toronto, ON, M5S 3G8, Canada

    Ali Dolatabadi

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  1. Vahid Jalilvand
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Jalilvand, V., Mohammadkhani, S., Ettouil, F.B. et al. Study on the Formation of (Co,Ni)O Solid Solution and Metallic Ni Phases During Suspension Plasma Spraying of CoO and NiO Powders. J Therm Spray Tech 32, 1167–1181 (2023). https://doi.org/10.1007/s11666-022-01505-x

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