Frictional Wear and Corrosion Behavior of AlCoCrFeNi High-Entropy Alloy Coatings Synthesized by Atmospheric Plasma Spraying.

High-entropy alloy coatings (HEAC) exhibit good frictional wear and corrosion resistances, which are of importance for structure materials. In this study, the microstructure, surface morphology, hardness, frictional wear and corrosion resistance of an AlCoCrFeNi high-entropy alloy coating synthesized by atmospheric plasma spraying (APS) were investigated. The frictional wear and corrosion resistance of the coating are simultaneously improved with an increase of the power of APS. The influence of the APS process on the microstructure and mechanical behavior is elucidated. The mechanisms of frictional wear and corrosion behavior of the AlCoCrFeNi HEAC are discussed in detail.

Evolution of the Microstructure and Mechanical Performance of As-Sprayed and Annealed Silicon Coating on Melt-Infiltrated Silicon Carbide Composites.

In this study, silicon coating was deposited on melt-infiltrated SiC composites using atmospheric plasma spraying and then annealed at 1100 and 1250 °C for 1-10 h to investigate the effect of annealing on the layer. The microstructure and mechanical properties were evaluated using scanning electron microscopy, X-ray diffractometry, transmission electron microscopy, nano-indentation, and bond strength tests. A silicon layer with a homogeneous polycrystalline cubic structure was obtained without phase transition after annealing. After annealing, three features were observed at the interface, namely ß-SiC/nano-oxide film/Si, Si-rich SiC/Si, and residual Si/nano-oxide film/Si. The nano-oxide film thickness was ≤100 nm and was well combined with SiC and silicon. Additionally, a good bond was formed between the silicon-rich SiC and silicon layer, resulting in a significant bond strength improvement from 11 to >30 MPa.

Long-Cycle Stability of In Situ Ultraviolet Curable Organic/Inorganic Composite Electrolyte for Solid-State Batteries.

Lithium-ion solid-state batteries with spinel Li4Ti5O12 (LTO) electrodes have significant advantages, such as stability, long life, and good multiplication performance. In this work, the LTO electrode was obtained by the atmospheric plasma spraying method, and a composite solid electrolyte was prepared by in situ ultraviolet (UV) curing on the LTO electrode. The composite solid electrolyte was designed using a soft-hard combination strategy, and the electrolyte was prepared into a composite of a poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP) flexible structure and high-conductivity Li1.3Al0.3Ti1.7(PO4)3 (LATP) hard particles. The composite electrolyte exhibited a good ionic conductivity up to 0.35 mS cm-1 at 30 °C and an electrochemical window above 4.0 V. In situ and ex situ electrolytes were assembled into LTO//electrolyte//Li solid-state batteries to investigate their impact on the electrochemical performance of the batteries. As a result, the assembled Li4Ti5O12//in situ electrolytes//Li batteries exhibited excellent rate of performance, and their capacity retention rate was 90% at 0.2 mA/cm2 after 300 cycles. This work provides a new method for the fabrication of novel advanced solid-state electrolytes and electrodes for applications in solid-state batteries.

Fabrication of Ni-Cu-W Graded Coatings by Plasma Spray Deposition and Laser Remelting.

In this study, Ni-Cu-W graded coatings are produced by atmospheric plasma spraying and subsequently remelted by laser. The surface morphology, hardness, compositional fluctuations and corrosion resistance of the Ni-Cu-W coating are investigated. The coatings after laser remelting are densified and become more homogenous with an excellent corrosion resistance and high hardness, which can be used to explore the new materials.

Human Gingival Fibroblast Adhesion and Proliferation on Hydroxyapatite-Coated Zirconia Abutment Surfaces.

Applying antibacterial coatings to dental implant materials seems reasonable but can have negative influences on desired cell adhesion and healing. In this study, zirconia abutment specimens interacting with gingival tissue were used. The aim was to compare the influence of machined or coated zirconia surfaces on the adhesion and proliferation of human gingival fibroblasts (HGF-1). Surface modifications were performed using atmospheric plasma coating with hydroxyapatite, zinc, and copper. Zirconia specimens were divided into four groups: hydroxyapatite, hydroxyapatite with zinc oxide (ZnO), hydroxyapatite with copper (Cu), and an untreated machined surface. After the characterization of the surface conditions, the morphology of adhered HGF-1 was determined by fluorescence staining and subjected to statistical evaluation. The visual analysis of cell morphology by SEM showed flat, polygonal, and largely adherent fibroblast cells in the untreated group, while round to partially flat cells were recorded in the groups with hydroxyapatite, hydroxyapatite + ZnO, and hydroxyapatite + Cu. The cell membranes in the hydroxyapatite + ZnO and hydroxyapatite + Cu groups appeared porous. The results show that HGF-1 adhere and proliferate well on machined zirconia, while plasma coating with hydroxyapatite or hydroxyapatite mixtures does not lead to increased adhesion or proliferation.

Effect of Varying Plasma Powers on High-Temperature Applications of Plasma-Sprayed Al0.5CoCrFeNi2Ti0.5 Coatings.

In this work, the microstructure and mechanical properties of atmospheric plasma-sprayed coatings of Al0.5CoCrFeNi2Ti0.5, prepared using gas-atomized powders at varying spray powers, are studied in as-sprayed and heat-treated conditions. Gas-atomized powders had spherical shapes and uniform element distributions, with major FCC phases and metastable BCC phases. The metastable BCC phase transformed to ordered and disordered BCC phases when sufficient energy was applied during the plasma-spraying process. During the heat treatment process for 2 hrs, disordered BCCs transformed into ordered BCCs, while the intensity of the FCC peaks increased. Spraying power plays a significant role in the microstructure and mechanical properties of plasma sprayed because at a high power, coatings exhibit better mechanical properties due to their dense microstructures resulting in less defects. As the plasma current was increased from 500 A to 700 A, the coatings' hardness increased by approximately 21%, which is directly proportional to the decreased wear rate of the coatings at high spraying powers. As the coatings experienced heat treatments, the coatings sprayed with a higher spraying power showed higher hardness and wear resistances. Precipitation strengthening played a significant role in the hardness and wear resistances of the coatings due to the addition of the titanium element.

Comparative Study on the Thermal Performance of Cr-CrxOy and YSZ-CoNiCrAlY Coatings Exposed at 900 °C.

Yttria stabilized zirconia (YSZ) thermal barrier coatings (TBCs) deposited on CoNiCrAlY oxidation protective bond coats are commonly required in temperature regimes up to 1200 °C (e.g., hot gas turbine regions) due to their superior thermal behavior and mechanical properties. For temperatures up to around 900 °C, oxidation protection can be alternatively provided by metallic-ceramic Cr-CrxOy coatings. For the present research, Cr-CrxOy atmospheric plasma sprayed (APS) and YSZ-CoNiCrAlY APS-high velocity oxy-fuel TBC coatings were deposited on a NiCr20Co18Ti substrate. The samples were isothermally heat treated at 900 °C for 10 h in an environmental atmosphere and subsequently isothermally oxidized at the same temperature for 1200 h. Investigations of the physical, chemical, and mechanical properties were performed on the as-sprayed, heat-treated, and oxidized samples. The oxidation behavior, microhardness, cohesion, and adhesion of the samples were correlated with the microstructural investigations and compared to the conventional TBC system. It could be shown that heat treating decreased the Cr-CrxOy coatings crack susceptibility and led to the formation of a protective thermally grown Cr oxide layer. The experimental work on the YSZ-CoNiCrAlY system revealed that the phase composition of the bond coat has a direct influence on the oxidation protection of the coating system.

In Vitro Bioactivity and Antibacterial Activity of Strontium-, Magnesium-, and Zinc-Multidoped Hydroxyapatite Porous Coatings Applied via Atmospheric Plasma Spraying.

The beneficial effects of Sr- and Mg-doped hydroxyapatite (HAp) on osteoblast proliferation and bone regeneration have been investigated in the past, and the antibacterial ability of Zn ions is well known. However, HAp coatings doped with these three elements via thermal spraying have not yet been investigated. In this study, HAp powder was synthesized at different pH values (4, 6, 8, and 10) and calcined at different temperatures (200, 400, 600, 800, and 1000 °C) to obtain HAp with the highest purity. Subsequently, strontium-, magnesium-, and zinc-doped HAp powders were synthesized at the optimal pH value and calcination temperature. The HAp powder was then coated onto Ti disks using atmospheric plasma spraying (APS) or vapor-induced pore-forming atmospheric plasma spraying (VIPF-APS) techniques at different working currents (350, 400, and 450 A) and spraying distances (10 and 15 cm). X-ray diffraction, Fourier transform infrared spectroscopy, and scanning electron microscopy equipped with energy-dispersive spectroscopy were used for material characterization to determine the optimal parameters. With these optimal coating parameters, HAp, Zn-HAp, SrMg-HAp, and ZnSrMg-HAp powders were deposited onto the Ti disks using VIPF-APS and named HAp-Ti, Zn-HAp-Ti, SrMg-HAp-Ti, and ZnSrMg-HAp-Ti, respectively. The in vitro bioactivity of these four groups was evaluated using a 3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide and alkaline phosphatase (ALPase) activity assay. Besides, the antibacterial activities against Prevotella nigrescens, Porphyromonas gingivalis, and Fusobacterium nucleatum were assessed. The results showed that the purity of HAp synthesized at pH 10 and 800 °C was 98.40%. A porous coating without cracks was obtained at a 10 cm spraying distance and 400 A working current using VIPF-APS. SrMg-HAp-Ti and ZnSrMg-HAp-Ti resulted in higher osteoblast proliferation and ALPase activity than the control. Moreover, both Zn-HAp-Ti and ZnSrMg-HAp-Ti exhibited antibacterial activity against the three bacteria. Therefore, ZnSrMg-HAp has potential as a coating for biomedical materials due to its ability to reduce bacterial infection and enhance osseointegration.

High-Temperature Corrosion of APS- and HVOF-Coated Nickel-Based Super Alloy under Air Oxidation and Melted Salt Domains.

Various thermal spraying approaches, such as air/atmospheric plasma spraying (APS) and high-velocity oxy-fuel (HVOF) spraying, are widely employed by plants owing to their flexibility, low costs and the high surface quality of the manufactured product. This study focuses on the corrosion behavior of a Ni superalloy coated with powder Cr3C2-25NiCr through APS and HVOF at 950 °C under air oxidation and Na2SO4 + 0.6V2O5 molten salt environments (MSE). The results show that HVOF-deposited Ni superalloys have higher hardness and bond strength than the respective APS coating. The thermo-gravimetric probe reveals that the Ni superalloys exposed to an oxidizing air environment has a minor mass gain compared to those under the MSE domain for both non-coated and coated samples, in line with the parabola curvature rate oxidizing law. The Ni superalloys show good corrosion resistance but poor oxidation resistance in APS-deposited Ni superalloys under the MSE. HVOF-coated Ni superalloys in both environments exhibit better corrosion resistance and lower mass gain than APS-coated superalloys. The excellent coating characteristics of HVOF-coated Ni superalloys lead to their better high-temperature corrosion performance than APS.

Study on the biological behaviors of CaP coatings with different morphology on carbon/carbon composites.

In this work, we designed and fabricated a CaP composite bio-coating with different surface morphologies on a carbon/carbon (C/C) matrix by means of hybrid supersonic atmospheric plasma spraying (SAPS) and microwave-hydrothermal (MH) technologies. We found that all studied coating materials can support mesenchymal stem cells (MSCs) proliferation with prolonged culture time (3 days and 7 days) in vitro. Furthermore, according to the (Confocal Laser Scanning Microscopy) CLSM results, the MSCs also showed good attachment and different spreading morphologies on SAPS/MH coatings. As such, C/C matrix, the MH treated coatings with needle-like and rod-like microstructures were chosen for further in vivo investigation. Considering the good bonding between host tissue and the studied materials, the in vivo morphology studies confirmed a good histocompatibility for all coating samples, as well as a decreasing expression for inflammatory factors in a physiological environment. The histological results around the implants indicated different cell aggregation and vascularization ability in the local micro-environment. In particular, based on the reduction of the C/C initial surface flaws (e.g. hydrophobicity, biological inertia and easily producing carbon fragments or particles), the MH treated coating with rod-like surface morphology with a specific surface area (~2.33 m2/g) and roughness (~13.80 µm), showed excellent performance as a promising implant in live tissue.

Depth-Sensing Indentation Creep Behavior of Nanostructured Thermal Barrier Coatings from As-Synthesized t'-8YSZ Feedstocks.

Nano-indentation is a popular method to characterize the micromechanical properties of nanostructured 8YSZ coatings. However, little research has focused on the creep behavior of nano-indentation and only the elastic modulus and nanohardness have been analyzed. Herein, for the first time, the nano-indentation creep behavior of plasma-sprayed nanostructured 8YSZ coatings using as-prepared nanostructured non-transformable tetragonal (t') feedstocks was investigated. The indentation creep behavior can be well characterized by the power-law equation and the strain rate sensitivity has been calculated in light of the equation. The strain rate sensitivity was sensitive to the load and the reasons were analyzed in detail. The current results can further guide and design thermal barrier coatings from the point of indentation creep property.

Axial Suspension Plasma Spraying: An ultimate technique to tailor Ti6Al4V surface with HAp for orthopaedic applications.

Dissolution of atmospheric plasma sprayed (APS) hydroxyapatite (HAp) coatings on Ti-6Al-4 V medical implants have always been a challenge to overcome in the field of biomedical industry. In the present work, an attempt has been made to develop a HAp coating using a novel thermal spray process called axial suspension plasma spraying (SPS), which leads to thin adherent coatings. Two HAp coatings fabricated by APS (P1 and P2) and four SPS HAp coatings (S1, S2, S3 and S4) produced with varying spraying parameters were characterized in terms of (1) microstructure, porosity, hardness, adhesion strength, contact angle and phase purity; (2) corrosion resistance in 10% Fetal bovine serum (FBS); (3) in-vitro cell adherence and cell viability using human umbilical cord blood-derived mesenchymal stem cells (hMSCs). Amongst different APS and SPS coatings, P1 and S3 exhibited superior properties. S3 coating developed using SPS exhibited 1.3 times higher adhesion strength when compared to APS coating (P1) and 9.5 times higher corrosion resistance than P1. In addition, both S3 and P1 exhibited comparatively higher biocompatibility as evidenced by the presence of more than 92% viable hMSCs.

Effect of substrate preheating treatment on the microstructure and ultrasonic cavitation erosion behavior of plasma-sprayed YSZ coatings.

Inconel 718 was used as the substrate and preheated at different temperatures to deposit yttrium stabilized zirconia (denoted as YSZ) coatings by atmospheric plasma spraying. The microstructure of the as-deposited YSZ coatings and those after cavitation-erosion tests were characterized by field emission scanning electron microscopy, Raman spectroscopy, and their hardness and toughness as well as cavitation-erosion resistance were evaluated in relation to the effect of substrate preheating temperature. Results indicate that the as-deposited YSZ coatings exhibit typical layered structure and consist of columnar crystals. With the increase of the substrate preheating temperature, the compactness and cohesion strength of coatings are obviously enhanced, which result in the increases in the hardness, elastic modulus and toughness as well as cavitation-erosion resistance of the ceramic coatings therewith. Particularly, the YSZ coating deposited at a substrate preheating temperature of 800 °C exhibits the highest hardness and toughness as well as the strongest lamellar interfacial bonding and cavitation-erosion resistance (its cavitation-erosion life is as much as 8 times than that of deposited at room temperature).

Microstructural Evolution of AlCoCrFeNiSi High-Entropy Alloy Powder during Mechanical Alloying and Its Coating Performance.

High-entropy alloys (HEAs) are promising structural materials due to their excellent comprehensive performances. The use of mechanically alloyed powders to deposit HEA coatings through atmospheric plasma spraying (APS) is an effective approach that can broaden the application areas of the HEAs. In this paper, a ductility-brittleness AlCoCrFeNiSi system was chosen as an object of study, and the detailed evolution of the surface morphology, particle size distribution, and microstructure of the powder during mechanical alloying was investigated. An AlCoCrFeNiSi HEA coating was deposited using powder milled for 10 h, which can be used as an ideal feedstock for APS. The surface morphology, microstructure, microhardness, and wear behavior of the coating at room temperature were investigated. The results showed that as the milling time increased, the particle size first increased, and then decreased. At the milling time of 10 h, simple body-centered cubic (BCC) and face-centered cubic (FCC) solid solution phases were formed. After spraying, the lamellar structure inside a single particle disappeared. An ordered BCC phase was detected, and the diffraction peaks of the Si element also disappeared, which indicates that phase transformation occurred during plasma spraying. A transmission electron microscopy analysis showed that nanometer crystalline grains with a grain size of about 30 nm existed in the APS coating. For the coating, an average microhardness of 612 ± 41 HV was obtained. Adhesive wear, tribo-oxidation wear, and slight abrasion wear took place during the wear test. The coating showed good wear resistance, with a volume wear rate of 0.38 ± 0.08 × 10-4 mm³·N-1·m-1, which makes it a promising coating for use in abrasive environments.

Comparison of Erosion Behavior and Particle Contamination in Mass-Production CF4/O2 Plasma Chambers Using Y2O3 and YF3 Protective Coatings.

Yttrium fluoride (YF3) and yttrium oxide (Y2O3) protective coatings prepared using an atmospheric plasma spraying technique were used to investigate the relationship between surface erosion behaviors and their nanoparticle generation under high-density plasma (1012-1013 cm-3) etching. As examined by transmission electron microscopy, the Y2O3 and YF3 coatings become oxyfluorinated after exposure to the plasma, wherein the yttrium oxyfluoride film formation was observed on the surface with a thickness of 5.2 and 6.8 nm, respectively. The difference in the oxyfluorination of Y2O3 and YF3 coatings could be attributed to Y-F and Y-O bonding energies. X-ray photoelectron spectroscopy analyses revealed that a strongly fluorinated bonding (Y-F bond) was obtained on the etched surface of the YF3 coating. Scanning electron microscopy and energy dispersive X-ray diffraction analysis revealed that the nanoparticles on the 12-inch wafer are composed of etchant gases and Y2O3. These results indicate that the YF3 coating is a more erosion-resistant material, resulting in fewer contamination particles compared with the Y2O3 coating.