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Processing and characterization of plasma-sprayed ceramic coatings on steel substrate: Part II. On coating performance

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Abstract

This investigation envisages the performance evaluation of a series of plasma-sprayed coatings from a few inexpensive powders, namely, alumina, plasma dissociated zircon (PDZ), zircon sand, and zircon-20 wt pct calcia. The hardness and adhesion (bond) strength of the coatings have been evaluated. All coatings offer an attractive thermal fatigue property. An added layer of yttria between the top and bond coats improves the thermal fatigue resistance appreciably. The wear performance of these coatings has also been evaluated using a “pin-on-disc” type wear testing setup. The Indian alumina coating offers a superior wear resistance and thermal fatigue property compared to an imported alumina coating. The coatings based on zirconia-silica offer an attractive thermal fatigue resistance along with an acceptable wear resistance. The latter improves considerably upon annealing of the coatings because of the removal of the residual stresses accumulated during deposition. Among these zirconia-silica-based coatings, the zircon-20 wt pct calcia is the most promising. The finishability of these coatings has been studied using a surface grinding setup equipped with a diamond wheel. The cutting forces and the surface roughness of the ground surface have been measured. The coatings have been found to possess a reasonably good grindability.

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Author notes

  1. P. P. Bandyopadhyay (Graduate Student, Lecturer)

    Present address: Department of Metallurgical and Materials Engineering, the Indian Institute of Technology, 721 302, Kharagpur, India

Authors and Affiliations

  1. Department of Metallurgical and Materials Engineering, the Indian Institute of Technology, 721 302, Kharagpur, India

    S. Das (Associate Professor), T. K. Bandyopadhyay (Graduate Student), S. Ghosh (Graduate Student) & A. B. Chattopadhyay (Professor)

  2. Department of Mechanical Engineering, B.E. College (DU), 711 103, Howrah, India

    P. P. Bandyopadhyay (Graduate Student, Lecturer)

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Das, S., Bandyopadhyay, T.K., Ghosh, S. et al. Processing and characterization of plasma-sprayed ceramic coatings on steel substrate: Part II. On coating performance. Metall Mater Trans A 34, 1919–1930 (2003). https://doi.org/10.1007/s11661-003-0157-2

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  • DOI: https://doi.org/10.1007/s11661-003-0157-2

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