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Obtaining and Analyzing the Al2O3-ZrO2 Ceramic Layers on Metallic Substrate

M. Luțcanu M. Coteață M.A. Bernevig C.D. Nechifor M.M. Cazacu P. Paraschiv B. Istrate G. Bădărău I.G. Sandu N. Cimpoeșu
Archives of Metallurgy and Materials | 2022 | vol. 67 | No 2 | 479-485 | DOI: 10.24425/amm.2022.137780
Keywords ceramic layer atmospheric plasma spraying SEM EDS
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Abstract

In this case ceramic layers from Metco ZrO2 and Al2O3 powders mixture (25/75; 50/50 and 75/25) were obtained through atmospheric plasma spraying (APS) after five passes on low carbon steel substrate. The sample surfaces mechanically grinded (160-2400) before and after ceramic layer deposition. Powder’s mixtures and the surface of ceramic thin layers were analyzed through: scanning electron microscopy (SEM). In order to understand the effect of surface wettability of the ceramic layers, before and after grinding the surface, three different liquids were used. Experimental results confirm the modification of the steel substrate surface characteristic from hydrophilic to hydrophobic when the ceramic layer was deposited. Surface free energy of hydration increases for all the samples with zirconia percentage addition before polishing process.
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Authors and Affiliations

M. Luțcanu
1 2
ORCID: ORCID
M. Coteață
3
ORCID: ORCID
M.A. Bernevig
1
ORCID: ORCID
C.D. Nechifor
2
ORCID: ORCID
M.M. Cazacu
2
ORCID: ORCID
P. Paraschiv
4
ORCID: ORCID
B. Istrate
5
ORCID: ORCID
G. Bădărău
1
ORCID: ORCID
I.G. Sandu
1
ORCID: ORCID
N. Cimpoeșu
1
ORCID: ORCID
  1. Gheorghe Asachi Technical University of Iasi, Faculty of Materials Science and Engineering, Prof.dr.doc. D. Mangeron no. 41 Street, 700050 Iasi, Romania
  2. "Gheorghe Asachi” Technical University of Iasi, Department of Physics, 700050 Iasi, Romania
  3. Gheorghe Asachi Tech Univ Iasi, Dept Machine Mfg Technol, 59A D Mangeron Blvd, Iasi 700050, Romania
  4. “Gheorghe Asachi” Technical University of Iasi, Department of Sport, 700050 Iasi, Romania
  5. Gheorghe Asachi Tech Univ Iasi, Fac Mech Engn 43 D Mangeron St, Iasi 700050, Romania

Evaluation of the Possibility of Applying Thermal Barrier Coatings to AlSi7Mg Alloy Castings

Marek Mróz Patryk Rąb
Archives of Foundry Engineering | 2023 | vol. 23 | No 3 | 104-109 | DOI: 10.24425/afe.2023.146668
Keywords thermal barrier coating aluminum-silicon alloy atmospheric plasma spraying
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Abstract

This paper analyses the possibility of applying thermal barrier coatings (TBCs) onto a substrate made of the AlSi7Mg alloy, intended for, among other things, internal combustion engine components. Engine components made of aluminum-silicon alloys, especially pistons and valve heads, are exposed to high temperature, pressure and thermal shock resulting from the combustion of the fuel-air mixture. These factors cause degradation of these components and can lead to damage. To minimize the risk of damage to engine components caused by heat stress, one way is to apply TBCs. Applying TBCs coatings to engine components improves their durability, increases power output and reduces fuel consumption. The research scope includes the application of an Al2O3-TiO3 coating via the APS (Air Plasma Spraying or Atmospheric Plasma Spraying) method onto a substrate of the AlSi7Mg alloy, analysis of the microstructure and chemical composition of the substrate and coating material, and assessment of the quality of the coating's bond with the AlSi7Mg alloy substrate using the scratch test method.
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Bibliography

[1] Chen, C., Sun, C., Wang, W., Qi, M., Han, W., Li, Y., Liu, X., Yang, F., Gou, L. & Guo, Z. (2022). Microstructure and mechanical properties of in-situ TiB2/AlSi7Mg composite via powder metallurgy and hot extrusion. Journal of Materials Research and Technology. 19, 1282-1292. https://doi.org/10.1016/j.jmrt.2022.05.117.
[2] Rambabu, P., Eswara Prasad, N., Kutumbarao, V.V., Wanhill, R.J.H. (2017). Aluminium Alloys for Aerospace Applications. In: Prasad, N., Wanhill, R. (eds) Aerospace Materials and Material Technologies . Indian Institute of Metals Series. Springer, Singapore. https://doi.org/10.1007/978-981-10-2134-3_2.
[3] Sonsino, C.M. & Franz, R. (2017). Multiaxial fatigue assessment for automotive safety components of cast aluminium EN AC-42000 T6 (G-AlSi7Mg0. 3 T6) under constant and variable amplitude loading. International Journal of Fatigue. 100(2), 489-501. https://doi.org/10.1016/j.ijfatigue.2016.10.027.
[4] Dolata, A.J., Dyzia, M., Jaworska, L. & Putyra, P. (2016). Cast hybrid composites designated for air compressor pistons. Archives of Metallurgy and Materials. 61(2A), 705-708. http://dx.doi.org/10.1515%2Famm-2016-0120.
[5] Siadkowska, K. & Czyż, Z. (2019). Selecting a material for an aircraft diesel engine block. Combustion Engines. 58(3), 4-8. DOI: http://dx.doi.org/10.19206/CE-2019-301.
[6] Floweday, G., Petrov, S., Tait, R.B. & Press, J. (2011). Thermo-mechanical fatigue damage and failure of modern high performance diesel pistons. Engineering Failure Analysis. 18(7), 1664-1674. https://doi.org/10.1016/j.engfailanal.2011.02.002.
[7] Azadi, M., Mafi, A., Roozban, M. & Moghaddam, F. (2012). Failure analysis of a cracked gasoline engine cylinder head. Journal of Failure Analysis and Prevention. 12, 286-294. https://doi.org/10.1007/s11668-012-9560-6.
[8] Krstic, B., Rasuo, B., Trifkovic, D., Radisavljevic, I., Rajic, Z. & Dinulovic, M. (2013). Failure analysis of an aircraft engine cylinder head. Engineering Failure Analysis. 32, 1-15. https://doi.org/10.1016/j.engfailanal.2013.03.004.
[9] Jing, G.X., Zhang, M.X., Qu, S., Pang, J.C., Fu, C.M., Dong, C., Li, S. X., Xu, C.G. & Zhang, Z.F. (2018). Investigation into diesel engine cylinder head failure. Engineering Failure Analysis. 90, 36-46. https://doi.org/10.1016/j.engfailanal.2018.03.008.
[10] Sharma, P., Dwivedi, V.K. & Kumar, D. (2021). A review on thermal barrier coatings (TBC) usage and effect on internal combustion engine. Advances in Fluid and Thermal Engineering: Select Proceedings of FLAME 2020, 77-85. https://doi.org/10.1007/978-981-16-0159-0_8.
[11] Dhomne, S. & Mahalle, A.M. (2019). Thermal barrier coating materials for SI engine. Journal of materials research and technology. 8(1), 1532-1537. https://doi.org/10.1016 /j.jmrt.2018.08.002.
[12] Gürbüz, H. (2022). Experimental investigation of the effects of ethanol‐diesel mixture on the performance and emissions of the thermal barrier coated diesel engine. Environmental Progress & Sustainable Energy. 41(1), e13718. https://doi.org/10.1002/ep.13718.

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Authors and Affiliations

Marek Mróz
ORCID: ORCID
Patryk Rąb
ORCID: ORCID

Effect of TiO₂ on the microstructure and phase composition of Al₂O₃ and Al₂O₃–TiO₂ APS sprayed coatings

Monika Michalak Leszek Łatka Paweł Sokołowski Rolando T. Candidato Jr. Andrzej Ambroziak
Bulletin of the Polish Academy of Sciences Technical Sciences | 2021 | 69 | 2 | e136735 | DOI: 10.24425/bpasts.2021.136735
Keywords coating atmospheric plasma spraying Al₂O₃ TiO₂
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Abstract

Plasma sprayed ceramic coatings serve as protective layers and are frequently exposed to aggressive wear, corrosion, or high-temperature environment. Currently, alumina and alumina-titania are some of the most popular protective ceramic composite coatings used in the industry. The present work deals with the investigation of the influence of TiO₂ content in the feedstock powder on the resulting microstructure and properties of Al₂O₃, Al₂O₃ + 3 wt% TiO₂, Al₂O₃ + 13 wt% TiO₂ and Al₂O₃ + 40 wt% TiO₂ coatings developed via atmospheric plasma spraying (APS). Specifically, the phase composition, morphology, and microstructure, as well as the mechanical and tribological performance of the coatings were examined. Results revealed that higher content of TiO₂ induced the transformation of phases, leading to the formation of intermediary Al₂TiO₅ and Al₂- xTi₁- xO₅ phases. Also, the dominant α–Al₂O₃ to γ–Al₂O₃ transformation confirmed the formulation of well-melted lamellas within the coating structure. It was also shown that the increase in TiO₂ content decreased the micro-hardness of the coatings due to the formation of the intermediary phases as mentioned above and thus, affected their tribological performance. The lowest volumetric wear, equal to 7.2×10⁻⁵ mm³/(N ∙ m), was reported for Al₂O₃ + 13 wt% TiO₂ coating.
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Authors and Affiliations

Monika Michalak
1
ORCID: ORCID
Leszek Łatka
1
ORCID: ORCID
Paweł Sokołowski
1
ORCID: ORCID
Rolando T. Candidato Jr.
2
ORCID: ORCID
Andrzej Ambroziak
1
ORCID: ORCID
  1. Faculty of Mechanical Engineering, Wroclaw University of Science and Technology, Wybrzeze Wyspianskiego 27, 50-370 Wroclaw, Poland
  2. Physics Department, College of Science and Mathematics, Mindanao State University-Iligan Institute of Technology, A. Bonifacio Avenue, Tibanga, 9200, Iligan, City, Philippines

Manufacture of MoO3 Coating Layer Using Thermal Spray Process and Analysis of Microstructure and Properties

Yu-Jin Hwang Kyu-Sik Kim Jae-Sung Park Kee-Ahn Lee
Archives of Metallurgy and Materials | 2022 | vol. 67 | No 4 | 1535-1538 | DOI: 10.24425/amm.2022.141089
Keywords MoO3 Thermal spray Atmospheric plasma spray Microstructure properties
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Abstract

MoO3 thick film was manufactured by using a thermal spray process (Atmospheric Plasma Spray, or APS) and its microstructure, phase composition and properties of the coating layer were investigated. Initial powder feedstock was composed of an orthorhombic α-MoO3 phase, and the average powder particle size was 6.7 μm. As a result of the APS coating process, a MoO3 coating layer with a thickness of about 90 μm was obtained. Phase transformation occurred during the process, and the coating layer consisted of not only α-MoO3 but also β-MoO3, MoO2. Phase transformation could be due to the rapid cooling that occurred during the process. The properties of the coating layer were evaluated using a nano indentation test. Hardness and reduced modulus were obtained as 0.47 GPa and 1.4 GPa, respectively. Based on the above results, the possibility of manufacturing a MoO3 thick coating layer using thermal spray is presented.
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Authors and Affiliations

Yu-Jin Hwang
1
ORCID: ORCID
Kyu-Sik Kim
1 2
ORCID: ORCID
Jae-Sung Park
3
Kee-Ahn Lee
1
ORCID: ORCID
  1. Inha University, Department of Materials Science and Engineering, Incheon, Korea
  2. Agency for Defense Development, Daejeon, Korea
  3. LT Metal, Seoul, Korea

Comparative Rolling Contact Behavior of Two APS Coatings with Different Matrix

D. Chicet S. Toma R. Haraga C. Bejinariu
Archives of Metallurgy and Materials | 2022 | vol. 67 | No 3 | 869-878 | DOI: 10.24425/amm.2022.139677
Keywords Rolling Contact Fatigue Atmospheric Plasma Spray Wear Path Microstructure
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Abstract

In this study we analyzed the rolling contact fatigue behavior of two types of coatings made by thermal coating, by the method of atmospheric plasma spraying (APS) from two commercially available powders: Ni5Al5Mo and Al2O3 – 13 TiO2. The contact fatigue behavior was studied on an installation specially designed. The specimens were tested for 54 hours (at 1380 rpm), at a load of 944 N. For both types of coatings, the appearance of a wear path was observed, much more obvious in the case of the Ni matrix layer, also confirmed by profilometry. The mechanism of the wear phenomenon was predominantly of plastic deformation type (the material was pushed towards the edges of the wear path) in the case of NiAlMo coating. In the case of ceramic coating, the wear path width was very small (300-450 μm), with very few changes at the surface level of the coating, which recommends this type of material for applications that require wear resistance to rolling.
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Authors and Affiliations

D. Chicet
1
ORCID: ORCID
S. Toma
1
ORCID: ORCID
R. Haraga
1
ORCID: ORCID
C. Bejinariu
1
ORCID: ORCID
  1. Gheorghe Asachi Technical University of Iasi, Department of Materials Science and Engineering, Blvd. Mangeron, No. 41, 700050, Iasi, Romania

Wear and Corrosion Properties of Pure Mo Coating Layer Manufactured by Atmospheric Plasma Spray Process

Yu-Jin Hwang Yurian Kim Soon-Hong Park Sung-Cheol Park Kee-Ahn Lee
Archives of Metallurgy and Materials | 2024 | vol. 69 | No 1 | 81-85 | DOI: 10.24425/amm.2024.147790
Keywords Thermal spray Atmospheric plasma spray coating Molybdenum Wear Corrosion
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Abstract

A pure molybdenum (Mo) coating layer was manufactured by using the atmospheric plasma spray (APS) process and its wear and corrosion characteristics were investigated in this study. A Mo coating layer was prepared to a thickness of approximately 480 μm, and it had sound physical properties with a porosity of 2.9% and hardness of 434 Hv. Room temperature dry wear characteristics were measured through a ball-on-disk test under load conditions of 5 N, 10 N and 15 N. Based on the coefficient of friction graph at 5 N and 10 N, the oxides formed during wear functioned as a wear lubricant, thereby confirming an increase in wear resistance. However, at 15 N, wear behavior changed, and wear occurred due to splat pulling out. A potentiodynamic polarization test was conducted under an artificial seawater atmosphere, and Ecorr and Icorr measured 0.717 V and 7.2E-5 A/cm2, respectively. Corrosion mainly occurred at the splat boundary and pores that were present in the initial state. Based on the findings above, the potential application of APS Mo coating material was also discussed.
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Authors and Affiliations

Yu-Jin Hwang
1
ORCID: ORCID
Yurian Kim
1
ORCID: ORCID
Soon-Hong Park
2
ORCID: ORCID
Sung-Cheol Park
3
ORCID: ORCID
Kee-Ahn Lee
1
ORCID: ORCID
  1. Inha University, Department of Materials Science and Engineering, Incheon, 22212, Republic of Korea
  2. POSCO Technical Research Laboratories, Gwangyang 57807, Republic of Korea
  3. Surface Treatment R&D Group, Korea Institute of Industrial Technology, Incheon, 21999, Republic of Korea

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