Theoretical design and experimental verification of high-entropy carbide ablative resistant coating

Composition design of high-entropy carbides is a topic of great scientific interest for the hot-end parts in the aerospace field.A novel theoretical method through an inverse composition design route,i.e.initially ensuring the oxide scale with excellent anti-ablation stability,is proposed to improve the ablation resistance of the highentropy carbide coatings.In this work,the(Hf_(0.36)Zr_(0.24)Ti_(0.1)Sc_(0.1)Y_(0.1)La_(0.1))C1-δ(HEC)coatings were prepared by the inverse design concept and verified by the ablation resistance experiment.The linear ablation rate of the HEC coatings is1.45μm/s,only 4.78%of the pristine HfC coatings after the oxyacetylene ablation at 4.18 MW/m2.The HEC possesses higher toughness with a higher Pugh's ratio of 1.55 in comparison with HfC(1.30).The in-situ formed dense(Hf_(0.36)Zr_(0.24)Ti_(0.1)Sc_(0.1)Y_(0.1)La_(0.1))O2-δoxide scale during ablation benefits to improve the anti-ablation performance attributed to its high structural adaptability with a lattice constant change not exceeding 0.19%at 2000-2300℃.The current investigation demonstrates the effectiveness of the inverse theoretical design,providing a novel optimization approach for ablation protection of high-entropy carbide coatings.

Preparation of micro-arc oxidation coatings on magnesium alloy and its thermal shock resistance property

In the NaAlO2-Na2SiO3 compound system, the ceramic coatings were prepared on magnesium alloy by micro-arc oxidation. The morphology, phase composition, and thermal shock resistance of the ceramic coatings were studied by scanning electron microscope, X-ray diffraction and thermal shock tests, respectively. The results showed that the ceramic coating contains MgO, MgAl2O4, as well as a little amount of MgESiO4. The thickness of the ceramic coatings increases with the current density increasing, when the current density is 12 A·dm^-2, the thermal shock resistance of the produced ceramic coating is the best. The hardness of the ceramic coating is up to 10 GPa or so.

Effect of single Si_(1−x)C_(x)coating and compound coatings on the thermal conductivity and corrosion resistance of Mg-3Sn alloy

A single Si_(1−x)C_(x)coating and compound coatings were deposited on Mg-3Sn matrix alloy by magnetron sputtering method.Compound coatings included Mg or Mg/AlTi intermediates between Mg-3Sn substrate and Si_(1−x)C_(x)coating.The thermal conductivity of the Mg-3Sn alloy after coating was enhanced at room temperature.The results showed that the Mg-3Sn alloy coated with Mg/AlTi/Si_(1−x)C_(x)displayed higher thermal conductivity,its thermal conductivity after corrosion was 90.1 W/(m K)and 108.4 W/(m K)at 25℃and 100℃,respectively.Meanwhile,it was revealed that the Mg/Si_(1−x)C_(x)and Mg/AlTi/Si_(1−x)C_(x)compound coatings had nobler Ecorr and much lower i_(corr),higher Rp,compared with the bare Mg-3Sn and Mg-3Sn/Si_(1−x)C_(x)system,and improved the corrosion resistance of the magnesium substrate.

Thermal Behavior of Nano-TiO_2 in Fire-Resistant Coating

The dispersion state of nano-TiO2 particles was studied by using transmission electron microscopy （TEM）and Fourier transform infrared spectroscopy （FT-IR）. Nanoparticles can be fully dispersed by specific hyperdispersant. The improvement of nano-TiO2 in thermal behavior and flame retardation of acrylic polymer and fire-resistant coating was investigated by differential thermal analysis （DTA）, thermogravimetry （TG）and fire-resistant time test. It is demonstrated that nano-TiO2 is helpful for enhancing the thermal stability,anti-oxidation and fire-resistant properties of acrylic polymer and fire-resistant coating.

Effect of Al-deposition on erosion resistance of plasma sprayed thermal barrier coating

A columnar Al film was firstly deposited on the top of 7%Y2O3？stabilized zirconia （7YSZ） ceramic coating in thermal barrier coating （TBC） system by magnetron sputtering. A vacuum treatment was then carried out at 700 °C for 1 h and 900 °C for 5 h to improve the erosion resistance of Al-deposited TBC. Aα-Al2O3 layer was in situ synthesized on the top of 7YSZ coating via vacuum heat treatment. The microstructure evolution of Al-deposited TBC illustrated that a loose surface-layer and a dense sub-layer formed on the top of 7YSZ coating after vacuum treatment. The phase structures of the as-sprayed TBC and the Al-deposited TBC after vacuum heat treatment were characterized by X-ray diffraction （XRD） and transmission electron microscope （TEM） assisted with focused ion beam （FIB）. Particulate erosion resistances of the as-sprayed TBC and treated TBC were compared at room temperature. In addition, erosion mechanism and schematic diagram were proposed. The results show that the Al-deposited TBC after vacuum heat treatment has better particulate erosion resistance than the as-sprayed one.

Enhancement of Corrosion Resistance of NiCrFeBSi Coatings Obtained by Flame Thermal Spray Process Adding an Electroless Nickel Coating Ni-P

Flame Thermal Spray (FTS) coatings frequently show some porosity and reduced adherence to substrate, which affect its properties, especially its corrosion resistance. In this work, the corrosion resistance of AISI 1018 carbon steel coated by different methods is compared: electroless nickel (EN) coating, NiCrFeBSi obtained by FTS, duplex coatings of an EN deposit on a layer of NiCrFeBSi obtained by FTS and a layer of NiCrFeBSi on an EN deposit. The coatings were characterized using optical microscopy and scanning electron microscopy techniques, EDS microprobe microanalysis, roughness as well as electrochemical polarization tests to obtain the corrosion rate. The results show the enhancement in the corrosion resistance in saline medium of the duplex coatings, especially of the EN coating on FTS layer.

Structure,mechanical and thermal properties of Y-doped CrAlN coatings

CrAlYN coatings with different Y contents(0,5 and 12 at.%)were deposited by cathodic arc evaporation to investigate the influence of Y-addition on the structure,mechanical and thermal properties of CrAlN coatings by using X-ray diffraction,scanning electron microscopy,differential scanning calorimetry,thermal gravimetric analysis and nanoindentation.The structural transformation of single phase cubic Cr_(0.42)Al_(0.58)N and Cr_(0.39)Al_(0.56)Y_(0.05)N coatings to cubic−wurtzite mixed Cr_(0.32)Al_(0.56)Y_(0.12)N coating leads to a drop in hardness from(30.2±0.7)GPa of Cr_(0.42)Al_(0.58)N and(32.0±1.0)GPa of Cr_(0.39)Al_(0.56)Y_(0.05)N to(25.2±0.7)GPa of Cr_(0.32)Al_(0.56)Y_(0.12)N.The incorporation of 5 at.%Y retards the thermal decomposition of CrAlN,verified by the postponed precipitation of w-AlN and N-loss upon annealing.Correspondingly,Cr_(0.39)Al_(0.56)Y_(0.05)N coating consistently exhibits the highest hardness value during thermal annealing.Nevertheless,alloying with Y exerts an adverse effect on the oxidation resistance of CrAlN.

Density Dependence of Tunnel Fire Resistance for Aerogel-Cement Mortar Coatings

Five kinds of mortars with density grades of 500, 600, 700, 800, and 900 kg/m3 were prepared. Their thermal conductivity and compressive strength were measured, and the morphological changes before and after simulated tunnel fire were observed. To investigate the fire resistance, the interfacial temperature of a 30 mm thick aerogel-cement mortar and self-compacting concrete (SCC) in a simulated tunnel fire with the maximum temperature of 1100 ℃ for 2.5 h was tested and recorded. The results showed that as the density decreased, both compressive strength and thermal conductivity of the aerogel-cement mortar exhibited an exponential decrease. The effective fire resistance time of the mortar with 500, 600, 700, 800, and 900 kg/m^3 for protecting SCC from tunnel fire were 97 min, 114 min, 144 min, > 150 min, 136 min, respectively. 700 - 800 kg/m3 was the optimum density for engineering application of tunnel concrete fireproof coating.

Improving Wear Resistance of the Ni-base Thermal Spray-Welding Coating Using Rare Earths

By adding rare earth alloy and cerium oxide, the effect of rare earths on tribological properties of nickel base alloy layer was studied to approach the possibility of applying rare earths to Ni base thermal spray welding coating. Wear test results showed that the wear rates of the nickel base coating without rare earths were quite high, and the load bearing capacity of coating was low, in contrast, the wear rates of the coating with rare earths were low and the coating had higher load bearing capacity. The results show that rare earths can refine the structure of nickel base alloy, improve the interface of the coating and substrate.

Thermal Shock Resistances of FeMnCr/Cr_3C_2 Coatings Deposited by Arc Spraying

Arc spraying with the cored wires was applied to deposit FeMnCr/Cr3C2 coatings on low carbon steel substrates, namely FM1, FM2 and FM3. Thermal shock resistances of the coatings were investigated to assess the influence of Cr3C2 content on thermal shock resistance. Characteristics of the coatings under thermal cycling test were studied by optical microscopy, field emission scanning electron microscope （FE-SEM） and energy dispersion spectrum （EDS）, X-ray diffraction （XRD）. The experimental results show that hardness of the coatings increases, bonding strength decreases slightly with increase of the Cr3C2 content of the coatings. As a result, FM2 coating possesses the best thermal shock resistance, attributing to its better thermal expansion matches and wettability than those of FM3 coating, less oxide rate than that of FM1 coating restraining from cracks formation and propagation in coatings.

Microstructure and properties of thermal-sprayed NiCrWRE coatings

The powders of NiCrW and NiCrWRE alloys were flame sprayed on a medium-carbon steel substrate by thermal spray welding. The micro- structure and tribological behavior of coatings were studied experimentally by means of scanning electron microscopy （SEM）, field emission gun scanning electron microscope （FEGSEM）, and wear tests. The addition of CeO2 modifies the coating morphology from a needle-like structure to a roughly cubic morphology; the refining and purifying effect of rare earth elements makes the microstmcture more compact and finer. Analysis of the worn surfaces reveals that the coatings with CeO2 addition show improved abrasive wear resistance over those without CeO2. By adding CeO2, the hardness of the coatings is significantly increased, and the wear resistance of the coatings is enhanced.

Microstructure and wear resistance of electro-thermal explosion sprayed stellite coating used for remanufacturing

Electro-thermal explosion directional spraying was used to prepare the stellite coating on substrate of the AISI 1045 steel. The morphologies of cross-section and worn scar, porosity, distribution of elements, micro- hardness and wear resistance of the coating were determined by means of SEM, EDAX, micro-hardness tester and sliding wear tester. Because of the compact construction, good bonding and high hardness, the coating is characterized by good wear resistance. The results show that the mainly failure mode of the stellite coating is micro- plowing.

Effects of Additive CeO_2 on Thermal Shock Resistance of Plasma-Sprayed Cr_2O_3 Coating

The influence of CeO2 with different content on the thermal shock resistance of plasmasprayed Cr2O3 coating was investigated. The thermal shock failure mechanism of coating was also studied. It is found that the thermal shock failure mechanism of coating is thermal stress fatigue destruction, and the destruction takes place at interface of ceramic and bond coating. The experimental results show that the lifetime of coating fracture and failure increase considerably when 3% CeO2 is added into the plasma-sprayed Cr2O3 coating. The suitable content of CeO2 makes the microcracks exist in network form. The microcrack net can release internal stress in coating, delay the crack forming and expanding and decrease holes in coating. Thus the thermal shock resistance increase largely.

Influence of Microstructures on Thermal Shock and Sintering Behavior of YSZ-based Thermal Barrier Coatings

In this study, two thermal barrier coatings based on YSZ were produced by using a commercially available agglomerated and sintered powder and a special spray powder prepared by high energy ball milling. Both thermal barrier coatings exhibited similar overall porosities, but significantly different microstructures. Application of the special spray powder prepared by high energy ball milling led to a microstructure with numerous inclusions of semi-molten agglomerates, which introduced a plethora of clusters of fine pores into the coating and several more microstructural defects. This microstructure resulted in a significantly better thermal shock behavior compared to the conventional thermal barrier coating. The heat treatment of both thermal barrier coatings atθ=1150℃for t=100 h led to a sintering of both coatings. The results were reduced overall porosity and significantly increased fracture toughness. A correlation between the fracture toughness of both coatings after the heat treatment and the thermal shock life time could not be identified.

High temperature cyclic oxidation behavior of Y_2O_3-ZrO_2 thermal barrier coatings irradiated by high-intensity pulsed ion beam

The high-temperature oxidation resistance behavior of 7% （mass fraction） Y203-ZrO2 thermal barrier coatings （TBCs） irradiated by high-intensity pulsed ion beam （HIPIB） was investigated under the cyclic oxidation condition of 1 050 ℃ and 1 h. The columnar grains in the TBCs disappear after the HIPIB irradiation at ion current densities of 100-200 A/cm^2 and the irradiated surface becomes smooth and densified after remelting and ablation due to the HIPIB irradiation. The thermally grown oxide （TGO） layer thickness of the irradiated TBCs is smaller than that of the original TBCs. After 15 cycles, the mass gains of the original TBCs and those irradiated by ion current densities of 100 and 200 A/cm^2 due to the oxidation are found to be 0.8-0.9, 0.6-0.7, and 0.3-0.4 mg/cm^2, respectively. The inward diffusion of oxygen through the irradiated TBCs is significantly impeded by the densified top layer formed due to irradiation, which is the main reason for the improved overall oxidation resistance of the irradiated TBCs.

Coating Resistant Refractory Castables YB/T 4193-20091

1 Scope This standard specifies the term, definition, classification, technical requirements, test methods, quality appraisal procedures, packing, marking, transportation, storage, and quality certificate of coating resistant refractory eastables.

High-temperature corrosion-resistance performance of electro-thermal explosion spraying coating

As a new spraying technology used in the remanufacturing engineering, electro-thermal explosion spraying holds a lot of advantages. Electro-thermal explosion spraying coating aliquation phenomena are reduced and non-crystal, micro-crystal and millimicron-crystal and other microstructure are formed. The corrosion-resistance ability of electro-thermal explosion spraying coating in high temperature environment was surveyed respectively. SEM equipped with EDS was employed to analyze the microstructure of spraying coating before and after corrosion. The corrosion-resistance mechanism of the spraying coating was discussed.

Preparation and properties of flame-sprayed Mo-FeB-Fe cermet coatings

The powders of Mo2FeB2 cermet were prepared with Mo powders, Fe-B alloy powders and Fe powders as raw materials. Mo2FeB2 cermet coatings were prepared on Q235 steel by reactive thermal spraying （RTS） method and heated at 1 000 ℃ in vacuum oven of 1 kPa for 5 h. The properties of coatings were investigated. The results indicate that Fe2B appears after milling for 15 h in the powder at room temperature, a part of ternary borides （Mo2FeB2） are generated in powder sintered at 900 ℃. The coatings are composed of the major phases Mo2FeB2 and a-Fe, a little of Fe203, FeO and some pores. The bonding strength between the substrate and the ceramic coating is 32.73 MPa, the thermal-shock times is about 43 and the wear resistance is enhanced by approximately 5.28 times compared with that of the substrate, respectively. The comprehensive properties of Mo2FeB2 cermet coatings can be imoroved further after vacuum heat-treatment at 1 000 ℃ for 5 h.

A Study of Low-Density Heat-Resistant Coating for New-Generation Launch Vehicle Fairings

In this paper,the properties of different low-density heat-resistant coating prescriptions were compared,and a heat-resistant coating with a density of 0.65 g/cm^(3),a tensile strength of 2.04 MPa,and a thermal conductivity of 0.126 W/(m·K)was obtained.The thermal performance of the coating was characterized by an oxygen-acetylene ablation test,a hot radiation test using a quartz lamp and in an arc-heated wind tunnel test.The results indicated that the low-density heat-resistant coating prescription has advantages of high temperature resistance,erosion resistance,ablative resistance and excellent heat resistance,which can satisfy the heat resistance requirements of new-generation launch vehicle fairings.The successful application of this heat-resistant coating technology resolved the problems of low efficiency and poor adhesive performance of the traditional hand-pasted cork process,and realized the rapid spray application of the thermal protection layer,effectively improved the manufacturing efficiency and production quality of the heat-resistant layer of new-generation launch vehicle fairings.

Structure of Micro-nano WC-10Co4Cr Coating and Cavitation Erosion Resistance in NaCl Solution

Cavitation erosion （CE） is the predominant cause for the failure of overflow components in fluid machinery. Advanced coatings have provided an effective solution to cavitation erosion due to the rapid development of surface engineering techniques. However, the influence of coating structures on CE resistance has not been sys- tematically studied. To better understand their relationship, micro-nano and conventional WC-10Co4Cr cermet coat- ings are deposited by high velocity oxygen fuel spray- ing（HVOF）, and their microstructures are analyzed by OM, SEM and XRD. Meanwhile, characterizations of mechan- ical and electrochemical properties of the coatings are carried out, as well as the coatings＇ resistance to CE in 3.5 wt % NaC1 solution, and the cavitation mechanisms are explored. Results show that micro-nano WC-10Co4Cr coating possesses dense microstructure, excellent mechanical and electrochemical properties, with very low porosity of 0.26 4-0.07% and extraordinary fracture toughness of 5.58 4-0.51 MPa.m1/2. Moreover, the CE resistance of micro-nano coating is enhanced above 50% than conventional coating at the steady CE period in 3.5 wt % NaC1 solution. The superior CE resistance of micro- nano WC-10Co4Cr coating may originate from the unique micro-nano structure and properties, which can effectively obstruct the formation and propagation of CE crack. Thus,a new method is proposed to enhance the CE resistance of WC-10Co4Cr coating by manipulating the microstructure.