Microstructure and Ablation Behavior of Low-Pressure Plasma Sprayed ZrB2 Coatings Down to 100 Pa.

The effect of chamber pressure on the microstructure and ablation behavior of ZrB2 coatings deposited by low-pressure plasma spraying was investigated. The results showed that as the spray chamber pressure further was reduced to less than 50 kPa, the porosity of the coating deposited at the same distance decreased with the chamber pressure, and the coating prepared under 100 Pa presented the lowest porosity of about 0.89%. The ablation performance test subjected to high-temperature plasma jet revealed that the linear ablation rate of ZrB2 coating increased with the porosity of the coating. As a result, among the ZrB2 coatings deposited at chamber pressures of 100 Pa, 5 kPa, 10 kPa and 50 kPa, the dense coating deposited at 100 Pa showed the lowest ablation rate of 0.33 µm/s. The dense ZrB2 coating with a thickness of about 100 µm was able to withstand 300 s ablation by a plasma flame with a net power of 25 kW resulting in an ablating coating surface temperature of about 2000 °C. The ablation mechanism of the coating was also examined.

Recent Research Advances in Plasma Spraying of Bulk-Like Dense Metal Coatings with Metallurgically Bonded Lamellae.

Although thermal spray metallic coatings have been widely used for materials protection from wear, corrosion and oxidation, its porous feature limits the full utilization of materials potential. Moreover, the oxidation inherent to thermal spraying in the ambient atmosphere is detrimental to interlamellar bonding formation, which further degrades the performance of thermal spray metal coatings. How to tape out the full potential of spray materials in the form of the coating is a still great challenge to thermal spray coating technology. Facing such challenge, recent efforts have been made to deposit dense metallic coatings with sufficiently bonded lamellae by oxide-free molten droplets through atmospheric plasma spraying. In this paper, the strategies for depositing bulk-like metal coatings will be reviewed. The formation of the bulk-like coating through post-spray treatments is briefly reviewed including post-spray heat treatment and laser remelting following the brief introduction to the features of thermal spray metallic coatings. The effect of the substrate preheating temperature on the splat formation and subsequently the adhesion formation was examined to reveal the dominant limitation of resultant oxide scale. Then, the role of the deposition temperature on the formation of bulk-like metal deposits with neglecting the effect of oxidation during spraying by vacuum plasma spraying practices is shortly presented. The recent progress on the new strategies to develop spread-fusing bonding mechanism and in-situ in-flight deoxidizing mechanism through developing ultra-hot metallic droplets will be introduced. The thermodynamics and kinetics requirements for the in-situ in-flight deoxidizing through deoxidizer elements adding to alloy spray powders for achieving oxide-free molten droplets in the ambient atmosphere are examined. The conditions to develop the spread-fusing mechanism during the spreading of impacting molten metal droplet for metallurgical bonding are presented. It is obvious from this review paper that the realization of two mechanisms depends on both the spray materials design and heating control of in-flight particles. Through the generation of ultra-hot droplets by plasma spraying to achieve oxide-free molten droplets, strategically it will be possible to deposit bulk-like dense metallic coating through spread-fusing of splat surfaces with limited post-spray oxidation. Such strategies will tape out the full potential of coating materials and open up the new application fields for plasma spraying.

Effect of Powder Particle Size and Spray Parameters on the Ni/Al Reaction During Plasma Spraying of Ni-Al Composite Powders.

It was known for long that Ni-Al composite powders can be used to deposit self-bonding coating as a bond coat for common ceramic coatings due to the exothermic reaction between Ni and Al. However, it was found that with commercial Ni-Al composite powders with a large particle size, it is difficult to ignite the self-propagating reaction between Ni and Al to form Ni-Al intermetallics by plasma spraying. In this study, Ni-Al composite powder particles of different sizes were used to prepare Ni-Al intermetallics-based coatings by plasma spraying. The dependencies of the exothermic reaction between Ni and Al and the coating microstructure on powder particle size and spray parameters were investigated. The phase composition, microstructure, porosity and oxide content of the coatings were characterized by x-ray diffraction, scanning electron microscope and image analyzing. The results show that particle size of Ni-Al composite powders is the dominant factor controlling the exothermic reaction for the formation of Ni-Al intermetallics during plasma spraying. When the powders larger than about 50 µm are used, the reaction forming aluminide cannot complete even by heating of plasma flame generated at high plasma arc power. However, when smaller powders less than 50 µm are used, the exothermic reaction can completely occur rapidly in plasma spraying, contributing to heating of Ni-Al droplets to the highest temperature for development of the self-bonding effect. The positive relationship between molten droplet temperature and tensile adhesive strength of the resultant coatings is recognized to confirm the contribution of high droplet temperature to the adhesive or cohesive strength.

Bioinspired Mechanically Robust Metal-Based Water Repellent Surface Enabled by Scalable Construction of a Flexible Coral-Reef-Like Architecture.

Mechanical robustness is a central concern for moving artificial superhydrophobic surfaces to application practices. It is believed that bulk hydrophilic materials cannot be use to construct micro/nanoarchitectures for superhydrophobicity since abrasion-induced exposure of hydrophilic surfaces leads to remarkable degradation of water repellency. To address this challenge, the robust mechanical durability of a superhydrophobic surface with metal (hydrophilic) textures, through scalable construction of a flexible coral-reef-like hierarchical architecture on various substrates including metals, glasses, and ceramics, is demonstrated. Discontinuous coral-reef-like Cu architecture is built by solid-state spraying commercial electrolytic Cu particles (15-65 µm) at supersonic particle velocities. Subsequent flame oxidation is applied to introduce a porous hard surface oxide layer. Owing to the unique combination of the flexible coral-reef-like architecture and self-similar manner of the fluorinated hard oxide surface layer, the coating surface retains its water repellency with an extremely low roll-off angle (<2°) after cyclic sand-paper abrasion, mechanical bending, sand-grit erosion, knife-scratching, and heavy loading of simulated acid rain droplets. Strong adhesion to glass, ceramics, and metals up to 34 MPa can be achieved without using adhesive. The results show that the present superhydrophobic coating can have wide outdoor applications for self-cleaning and corrosion protection of metal parts.