Improvement of adhesion and cohesion in plasma-sprayed ceramic coatings by heterogeneous modification of nonbonded lamellar interface using high strength adhesive infiltration

Journal of Thermal Spray Technology

Volumn 22, Issue 1, 2013, Pages 36-47

  Yang, Guan Jun ^a   Li, Chang Jiu ^a   Li, Cheng Xin ^a   Kondoh, Katsuyoshi ^b   Ohmori, Akira ^b  

^a XI'AN JIAOTONG UNIVERSITY   (China)

^b OSAKA UNIVERSITY   (Japan)

Author keywords

adhesive infiltration; adhesive strength; ceramic coating; cohesion; erosion resistance; plasma spraying

Indexed keywords

ADHESIVE INFILTRATION; ADHESIVE STRENGTH; COATING SURFACE; COHESION; ELEMENT DISTRIBUTION MAPS; EROSION RESISTANCE; HIGH STRENGTH; JET ANGLE; LAMELLAR INTERFACES; LARGE PARTICLES; LOW ADHESION; PLASMA-SPRAYED CERAMIC COATINGS; SMALL PARTICLES;

ALUMINUM COATINGS; CERAMIC COATINGS; EROSION; INTERFACES (MATERIALS); MECHANICAL PROPERTIES; PLASMA SPRAYING;

ADHESION;

EID: 84872613715     PISSN: 10599630     EISSN: None     Source Type: Journal    
DOI: 10.1007/s11666-012-9831-5     Document Type: Article

References (91)

1. R.W. Smith, Plasma Spray Processing - The State of the Art and Future from a Surface to a Materials Processing Technology, Proceedings of 2nd Plasma-Technik-Symposium, S. Blum-Sandmeier, H. Eschnauer, P. Huber, and A. R. Nicoll, Ed., Lucerne/Switzerland, 1991, p 17-38
2. C.C. Berndt, and P. Ostojic, Strength Testing of Plasma Sprayed Coatings, Proceedings of International Symposium on Advanced Thermal Spraying Technology and Allied Coatings, 1988 (Osaka, Japan), Japan High Temperature Society, 1988, p 191-197
3. A. Hasui, S. Kitahara, and T. Fukushima, On Relation Between Properties of Coating and Spraying Angle in Plasma Jet Spraying, Trans. Natl. Res. Inst. Met., 1970, 12(1), p 9-20
4. 2 Coatings on AISI, 316L Stainless Steel, Vacuum, 2005, 77(3), p 315-321
5. C.R.C. Lima and R.D. Trevisan, Temperature Measurements and Adhesion Properties of Plasma Sprayed Thermal Barrier Coatings, J. Therm. Spray Technol., 1999, 8(2), p 323-327
6. C.-J. Li and A. Ohmori, Relationships Between the Microstructure and Properties of Thermally Sprayed Deposits, J. Therm. Spray Technol., 2002, 11(3), p 365-374
7. R.W. Rice, Microstructure Dependence of Mechanical Behavior of Ceramics, Properties and Microstructure, Treatise on Materials Science and Technology, R.K. MacCrone, Ed., Academic Press, New York, 1977, p 199-381
8. L. Pawlowski, The Science and Engineering of Thermal Spray Coatings, John Wiley & Sons Inc., New York, 1995, p 193
9. J. Knuuttila, P. Sorsa, and T. Mantyla, Sealing of Thermal Spray Coatings by Impregnation, J. Therm. Spray Technol., 1999, 8(2), p 249-257
10. M. Rosso, A. Scrivani, D. Ugues, and S. Bertini, Corrosion Resistance and Properties of Pump Pistons Coated with Hard Materials, Int. J. Refract. Met. Hard Mater., 2001, 19(1), p 45-52
11. P.P. Psyllaki, M. Jeandin, and D.I. Pantelis, Microstructure and Wear Mechanisms of Thermal-Sprayed Alumina Coatings, Mater. Lett., 2001, 47(1-2), p 77-82
12. 2 Coating at Elevated Temperatures, Ceram. Int., 2001, 27(3), p 251-260
13. A. Ohmori, Y. Arata, and C.-J. Li, Basic Study on Properties of Plasma Sprayed Ceramic Coatings, Trans. Jpn. Weld. Res. Inst., 1986, 15, p 339-348
14. R. McPherson, and C.C. Berndt, A Fracture Mechanics Approach to the Adhesion of Flame and Plasma Sprayed Coatings, Proceedings of 9th International Thermal Spraying Conference, (Hague/Netherlands), 1980, p 310-316
15. 2 Thermal Barrier Coatings, Surf. Coat. Technol., 2000, 123(2-3), p 147-158
16. P.J. Callus and C.C. Berndt, Relationships Between the Mode II, Fracture Toughness and Microstructure of Thermal Spray Coatings, Surf. Coat. Technol., 1999, 114(2-3), p 114-128
17. 3 Coating by Using Copper Electroplating, Thin Solid Films, 1991, 201(2), p 241-252
18. 3 Coating, Surf. Coat. Technol., 1996, 82(3), p 254-258
19. C. Takahashi, and T. Senda, On the Pore Structure of Plasma Sprayed Films, Thermal Spraying: Current Status and Future Trends, A. Ohmori, Ed., 1995 (Kobe, Japan), High Temperature Society of Japan, 1995, p 921-926
20. Y.-Z. Xing, C.-J. Li, Q. Zhang, C.-X. Li, and G.-J. Yang, Influence of Microstructure on the Ionic Conductivity of Plasma-Sprayed Yttria-Stabilized Zirconia Deposits, J. Am. Ceram. Soc., 2008, 91(12), p 3931-3936
21. Y.-Z. Xing, C.-J. Li, C.-X. Li, and G.-J. Yang, Influence of Through-Lamella Grain Growth on Ionic Conductivity of Plasma-Sprayed Yttria-Stabilized Zirconia as an Electrolyte in Solid Oxide Fuel Cells, J. Power Sources, 2008, 176(1), p 31-38
22. 3 Coatings, J. Therm. Spray Technol., 2011, 20(1-2), p 160-169
23. K.A. Khor, A. Vreeling, Z.L. Dong, and P. Cheang, Laser Treatment of Plasma Sprayed HA Coatings, Mater. Sci. Eng., A, 1999, 266(1-2), p 1-7
24. 3 Coatings Prepared by a Laser Hybrid Spraying Technique, Thin Solid Films, 2002, 415(1-2), p 160-166
25. P.C. Tsai, J.H. Lee, and C.L. Chang, Improving the Erosion Resistance of Plasma-sprayed Zirconia Thermal Barrier Coatings by Laser Glazing, Surf. Coat. Technol., 2007, 202(4-7), p 719-724
26. 2 Coating by APS, Mater. Sci. Technol., 2011, 27(1), p 194-200
27. 2 Coatings, Mater. Manuf. Processes, 2002, 17(2), p 157-167
28. G. Antou, G. Montavon, F. Hlawka, A. Cornet, C. Coddet, and F. Machi, Modification of Thermal Barrier Coating Architecture by In Situ Laser Remelting, J. Eur. Ceram. Soc., 2006, 26(16), p 3583-3597
29. R. Krishnan, S. Dash, R. Kesavamoorthy, C.B. Rao, A.K. Tyagi, and B. Raj, Laser Surface Modification and Characterization of Air Plasma Sprayed Alumina Coatings, Surf. Coat. Technol., 2006, 200(8), p 2791-2799
30. C. Batista, A. Portinha, R.M. Ribeiro, V. Teixeira, M.F. Costa, and C.R. Oliveira, Morphological and Microstructural Characterization of Laser-Glazed Plasma-Sprayed Thermal Barrier Coatings, Surf. Coat. Technol., 2006, 200(9), p 2929-2937
31. 2 Coatings on a Low-Carbon Steel, Surf. Coat. Technol., 1992, 52(2), p 141-144
32. K.M. Jasim, R.D. Rawlings, and D.R.F. West, Characterization of Plasma-Sprayed Layers of Fully Yttria-Stabilized Zirconia Modified by Laser Sealing, Surf. Coat. Technol., 1992, 53(1), p 75-86
33. A. Petitbon, L. Boquet, and D. Delsart, Laser Surface Sealing and Strengthening of Zirconia Coatings, Surf. Coat. Technol., 1991, 49(1-3), p 57-61
34. M. Inada, T. Maeda, and M. Inada, HIP of Plasma Spray Coated Ceramics, Proceedings of International Symposium on Advanced Thermal Spraying Technology and Allied Coatings, Japan High Temperature Society, 1988, p 211-215
35. K.A. Khor, Hot Isostatic Pressing Modifications of Pore Size Distribution in Plasma Sprayed Coatings, Mater. Manuf. Processes, 1997, 12(2), p 291-307
36. C. Zhang, G. Zhang, S. Leparoux, H. Liao, C.-X. Li, C.-J. Li, and C. Coddet, Microwave Sintering of Plasma-Sprayed Yttria Stabilized Zirconia Electrolyte Coating, J. Eur. Ceram. Soc., 2008, 28(13), p 2529-2538
37. B.Z. Janos, E. Lugscheider, and P. Remer, Effect of Thermal Aging on the Erosion Resistance of Air Plasma Sprayed Zirconia Thermal Barrier Coating, Surf. Coat. Technol., 1999, 113(3), p 278-285
38. B. Prawara, H. Yara, Y. Miyagi, and T. Fukushima, Spark Plasma Sintering as a Post-Spray Treatment for Thermally-Sprayed Coatings, Surf. Coat. Technol., 2003, 162(2-3), p 234-241
39. J.A. Thompson and T.W. Clyne, The Effect of Heat Treatment on the Stiffness of Zirconia Top Coats in Plasma-Sprayed TBCs, Acta Mater., 2001, 49(9), p 1565-1575
40. A. Cipitria, I.O. Golosnoy, and T.W. Clyne, A Sintering Model for Plasma-sprayed Zirconia TBCs. Part I: Free-standing Coatings, Acta Mater., 2009, 57(4), p 980-992
41. A. Cipitria, I.O. Golosnoy, and T.W. Clyne, A Sintering Model for Plasma-sprayed Zirconia Thermal Barrier Coatings. Part II: Coatings Bonded to a Rigid Substrate, Acta Mater., 2009, 57(4), p 993-1003
42. N.N.K. Miyajima, Y. Harada, and H. Nakahira, Refining of Sprayed Oxide Coating by Chemically Densifying Method, J. Jpn. High Temp. Soc., 1992, 18(Suppl), p 307-313
43. C.-J. Li, C.-X. Li, and X.-J. Ning, Performance of YSZ Electrolyte Layer Deposited by Atmospheric Plasma Spraying for Cermet-Supported Tubular SOFC, Vacuum, 2004, 73(3-4), p 699-703
44. C.-J. Li, X.-J. Ning, and C.-X. Li, Effect of Densification Processes on the Properties of Plasma-Sprayed YSZ Electrolyte Coatings for Solid Oxide Fuel Cells, Surf. Coat. Technol., 2005, 190(1), p 60-64
45. X.-J. Ning, C.-X. Li, C.-J. Li, and G.-J. Yang, Modification of Microstructure and Electrical Conductivity of Plasma-Sprayed YSZ Deposit Through Post-Densification Process, Mater. Sci. Eng., A, 2006, 428(1-2), p 98-105
46. M. Vippola, S. Ahmaniemi, J. Keranen, P. Vuoristo, T. Lepisto, T. Mantyla, and E. Olsson, Aluminum Phosphate Sealed Alumina Coating: Characterization of Microstructure, Mater. Sci. Eng., A, 2002, 323(1-2), p 1-8
47. K. Niemi, P. Sorsa, P. Vuoristo, and T. Mantyla, Thermal Spray Alumina Coatings with Strongly Improved Wear and Corrosion Resistance, Thermal Spray Industrial Applications, C.C. Berndt and S. Sampath, Ed., ASM International, 1994, p 533-536
48. 3 Coatings Sealed by Aluminum Phosphates, J. Therm. Spray Technol., 1997, 6(2), p 205-210
49. S. Ahmaniemi, M. Vippola, P. Vuoristo, T. Mantyla, M. Buchmann, and R. Gadow, Residual Stresses in Aluminium Phosphate Sealed Plasma Sprayed Oxide Coatings and Their Effect on Abrasive wear, Wear, 2002, 252(7-8), p 614-623
50. M. Vippola, S. Ahmaniemi, P. Vuoristo, T. Lepisto, T. Mantyla, and E. Olsson, Microstructural Study of Aluminum Phosphate-Sealed, Plasma-Sprayed Chromium Oxide Coating, J. Therm. Spray Technol., 2002, 11(2), p 253-260
51. 3 Coatings, J. Mater. Sci. Lett., 2003, 22(6), p 463-466
52. T. Troczynski, Q. Yang, and G. John, Post-deposition Treatment of Zirconia Thermal Barrier Coatings Using Sol-Gel Alumina, J. Therm. Spray Technol., 1999, 8(2), p 229-234
53. B.R. Marple, J. Voyer, and P. Bechard, Sol Infiltration and Heat Treatment of Alumina-Chromia Plasma-sprayed Coatings, J. Eur. Ceram. Soc., 2001, 21(7), p 861-868
54. T. Mantyla, P. Vuoristo, and P. Kettunen, Chemical Vapor-Deposition Densification of Plasma-Sprayed Oxide Coatings, Thin Solid Films, 1984, 118(4), p 437-444
55. V.A.C. Haanappel, J.B.A. Scharenborg, H.D. Vancorbach, T. Fransen, and P.J. Gellings, Can Thermal Barrier Coatings Be Sealed by Metal-Organic Chemical-Vapor-Deposition of Silica and Alumina, High Temp. Mater. Processes (London), 1995, 14(2), p 57-66
56. E. Lugscheider, P. Jokiel, V. Messerschmidt, and G. Beckschulte, Subsequent Sealing of Thermal Spray Coatings to Increase Corrosion Resistance, Surf. Eng., 1994, 10(1), p 46-51
57. B. Wielage, U. Hofmann, S. Steinhauser, and G. Zimmermann, Improving Wear and Corrosion Resistance of Thermal Sprayed Coatings, Surf. Eng., 1998, 14(2), p 136-138
58. H.J. Kim, C.H. Lee, and Y.G. Kweon, The Effects of Sealing on the Mechanical Properties of the Plasma-Sprayed Alumina-Titania Coating, Surf. Coat. Technol., 2001, 139(1), p 75-80
59. H.J. Kim, S. Odoul, C.H. Lee, and Y.G. Kweon, The Electrical Insulation Behavior and Sealing Effects of Plasma-Sprayed Alumina-Titania Coatings, Surf. Coat. Technol., 2001, 140(3), p 293-301
60. S. Liscano, L. Gil, and M.H. Staia, Correlation Between Microstructural Characteristics and the Abrasion Wear Resistance of Sealed Thermal-Sprayed Coatings, Surf. Coat. Technol., 2005, 200(5-6), p 1310-1314
61. S. Liscano, L. Gil, and M.H. Staia, Effect of Sealing Treatment on the Corrosion Resistance of Thermal-Sprayed Ceramic Coatings, Surf. Coat. Technol., 2004, 188-189, p 135-139
62. P. Ctibor, K. Neufuss, F. Zahalka, and B. Kolman, Plasma Sprayed Ceramic Coatings without and with Epoxy Resin Sealing Treatment and Their Wear Resistance, Wear, 2007, 262(9-10), p 1274-1280
63. 3 Coating by Adhesives Impregnation, J. Mater. Sci. Lett., 2003, 22(21), p 1499-1501
64. H. Ito, R. Nakamura, and M. Shiroyama, Infiltration of Copper into Titanium-Molybdenum Spray Coatings, Surf. Eng., 1988, 4(1), p 35-38
65. A. Ohmori, Z. Zhou, and K. Inoue, Liquid-Mn Sintering of Plasma-Sprayed Zirconia Yttria Coatings, Thin Solid Films, 1994, 251(2), p 141-146
66. 2 Coating by Liquid Mn Alloys, J. Therm. Spray Technol., 1996, 5(2), p 134-138
67. A. Ohmori, C.-J. Li, and Y. Arata, Fundamental Properties of the ACT-JP (Arata Coating Test with Jet Particles), Thermal Spray: Advances in Coatings Technology, D.L. Houck, Ed., 1987 (Orlando, FL), ASM International, 1988, p 79-83
68. 2-NiCr Coating, J. Mater. Sci. Lett., 1999, 18(21), p 1719-1721
69. J. Karthikeyan, A.K. Sinha, and A.R. Biswas, Impregnation of Thermally Sprayed Coatings for Microstructure Studies, J. Therm. Spray Technol., 1996, 5(1), p 74-78
70. C.-J. Li, A. Ohmori, and R. McPherson, The Relationship Between Microstructure and Young's Modulus of Thermally Sprayed Ceramic Coatings, J. Mater. Sci., 1997, 32(4), p 997-1004
71. S. Kuroda and T.W. Clyne, The Quenching Stress in Thermally Sprayed Coatings, Thin Solid Films, 1991, 200(1), p 49-66
72. Y. Arata, A. Ohmori, and C.-J. Li, Electrochemical Method to Evaluate the Connected Porosity in Ceramic Coatings, Thin Solid Films, 1988, 156(2), p 315-325
73. C. Zhang, W.-Y. Li, M.P. Planche, C.-X. Li, H.L. Liao, C.-J. Li, and C. Coddet, Study on Gas Permeation Behaviour Through Atmospheric Plasma-Sprayed Yttria Stabilized Zirconia Coating, Surf. Coat. Technol., 2008, 202(20), p 5055-5061
74. A. Mirahmadi and K. Valefi, Densification of Plasma Sprayed SOFC Electrolyte Layer Through Infiltration with Aqueous Nitrate Solution, J. Fuel Cell Sci. Technol., 2012, 9(1), p 011001
75. R.J. Damani and P. Makroczy, Heat Treatment Induced Phase and Microstructural Development in Bulk Plasma Sprayed Alumina, J. Eur. Ceram. Soc., 2000, 20(7), p 867-888
76. C.-J. Li and W.-Z. Wang, Quantitative Characterization of Lamellar Microstructure of Plasma-Sprayed Ceramic Coatings Through Visualization of Void Distribution, Mater. Sci. Eng., A, 2004, 386(1-2), p 10-19
77. J. Pech and B. Hannoyer, Influence of Oxide Layer Promoted by d.c. Plasma Preheating on the Adhesion Coating and Role of the Initial Surface Pretreatment, Surf. Interface Anal., 2000, 30(1), p 585-588
78. T. Chraska and A.H. King, Effect of Different Substrate Conditions upon Interface with Plasma Sprayed Zirconia - A TEM Study, Surf. Coat. Technol., 2002, 157(2-3), p 238-246
79. C.-J. Li and J.-L. Li, Evaporated-Gas-Induced Splashing Model for Splat Formation During Plasma Spraying, Surf. Coat. Technol., 2004, 184(1), p 13-23
80. X.Y. Jiang, Y.P. Wan, H. Herman, and S. Sampath, Role of Condensates and Adsorbates on Substrate Surface on Fragmentation of Impinging Molten Droplets During Thermal Spray, Thin Solid Films, 2001, 385(1-2), p 132-141
81. W. Funk, F. Goebe, and M. Mauz, The Influence of Substrate Temperature on the Bonding Strength of Plasma Sprayed Oxide Ceramics, Proceedings of 1st Plasma-Technik-Symposium, Plasma-Technik AG, Wohlen, Switzerland, 1988, p 59-66
82. G. Barbezat, and K. Landes, Plasma Technology Triplex for the Deposition of Ceramic Coatings in the Industry, Thermal Spray: Surface Engineering Via Applied Research, C.C. Berndt, Ed., 2000 (Montreal, Quebec, Canada), ASM International, 2000, p 881-885
83. G. Barbezat, The Internal Plasma Spraying on Powerful Technology for the Aerospace and Automotive Industries, Thermal Spray 2001: New Surfaces for a New Millennium, C.C. Berndt, K.A. Khor, and E.F. Lugscheider, Ed., 2001 (Singapore), ASM International, 2001, p 135-139
84. C.R.C. Lima and J.M. Guilemany, Adhesion Improvements of Thermal Barrier Coatings with HVOF Thermally Sprayed Bond Coats, Surf. Coat. Technol., 2007, 201(8), p 4694-4701
85. W. Shen, F.C. Wang, Q.B. Fan, Z.A. Ma, and X.W. Yang, Finite Element Simulation of Tensile Bond Strength of Atmospheric Plasma Spraying Thermal Barrier Coatings, Surf. Coat. Technol., 2011, 205(8-9), p 2964-2969
86. S.A. Sadeghi-Fadaki, K. Zangeneh-Madar, and Z. Valefi, The Adhesion Strength and Indentation Toughness of Plasma-sprayed Yttria Stabilized Zirconia Coatings, Surf. Coat. Technol., 2010, 204(14), p 2136-2141
87. 3 Coatings, Trans. Jpn. Weld. Res. Inst., 1990, 19, p 259-270
88. C.-J. Li, G.-J. Yang, and A. Ohmori, Relationship Between Particle Erosion and Lamellar Microstructure for Plasma-Sprayed Alumina Coatings, Wear, 2006, 260(11-12), p 1166-1172
89. Y.I. Oka, S. Mihara, and T. Yoshida, Impact-Angle Dependence and Estimation of Erosion Damage to Ceramic Materials Caused by Solid Particle Impact, Wear, 2009, 267(1-4), p 129-135
90. H.M. Hawthorne, L.C. Erickson, D. Ross, H. Tai, and T. Troczynski, The Microstructural Dependence of Wear and Indentation Behaviour of some Plasma-Sprayed Alumina Coatings, Wear, 1997, 203, p 709-714
91. A. Ohmori, and C.-J. Li, Evaluation of the Lamellar Bonding of Ceramic Coating by Particle Erosive Test, Thermal Spraying: Current Status and Future Trends, A. Ohmori, Ed., 1995 (Kobe, Japan), High Temperature Society of Japan, 1995, p 967-972