Coarse WC Particles Ceramic-Metal Composite Coating by Laser Cladding

The coarse WC particles ceramic-metal com- posite coatings with WC density of 67 wt-% and thickness of 1.0-1.2 mm have been cladded on 20Ni4Mo steel surface by a 2 kW CO_2 laser.The sintered WC particles with the size of 600-1000 μm are chosen as the main strengthening phase, Ni-base self-flux alloy as the binder in the compo- site coatings.The microstructure and microhardness of both WC particles and binder are analysed.The rigid ball indention with acoustic emission technique is used to evaluate the brittleness of the coating.Finally,the abrasive wear resistance of the coating is tested.Besides,the coatings with the same ratio and size of WC parti- cles in low carbon steel tube rod were cladded on 20Ni4Mo steel by atomic hydrogen welding tech- nique and analysed by the same way,their results are compared.

Cracked elastic substrate strip with functionally graded coating under thermal-mechanical loading

This paper investigates the functionally graded coating bonded to an elastic strip with a crack under thermal- mechanical loading. Considering some new boundary conditions, it is assumed that the temperature drop across the crack surface is the result of the thermal conductivity index which controls heat conduction through the crack region. By the Fourier transforms, the thermal-elastic mixed boundary value problems are reduced to a system of singular integral equations which can be approximately solved by applying the Chebyshev polynomials. The numerical computation methods for the temperature, the displacement field and the thermal stress intensity factors （TSIFs） are presented. The normal temperature distributions （NTD） with different parameters along the crack surface are analyzed by numerical examples. The influence of the crack position and the thermal-elastic non- homogeneous parameters on the TSIFs of modes I and 11 at the crack tip is presented. Results show that the variation of the thickness of the graded coating has a significant effect on the temperature jump across the crack surfaces when keeping the thickness of the substrate constant, and the thickness of functionally graded material （FGM） coating has a significant effect on the crack in the substrate. The results can be expected to be used for the purpose of gaining better understanding of the thermal-mechanical behavior of graded coatings.

MICROSTRUCTURE OF NiCoCrAlY COMPONENT IN PLASMA SPRAYED ZrO_2/NiCoCrAlY GRADED COATING

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In-Situ Synthesis and Characteristics of TiC-Fe Cermet Graded Composite Coating on a Steel Substrate

By means of an inherent elevated-temperature of poured liquid steel,a Ti-C-30wt%Fe preform,which was pre-placed in a mould cavity,was directly ignited and a combustion synthesis reaction took place.As a result,a TiC-Fe cermet coating with a thickness of about 10mm was simultaneously synthesized on the solidified steel matrix.The synthesized coating exhibits a feature of graded composite structure,in which both the amount and size of TiC particles decrease gradually with an increasing distance from the furface of the coating.Moreover,by a proper casting technique,the pores formed during the combustion synthesis of the preform could be centrally distributed in 2-3mm in outer layer of the coating.When this outer porous layer was worn off,the rest coating with a thickness of about 8mm possesses a dense structure and a high abrasive wear resistance.

Preparation of Ti6Al4V/BG/HA graded coating by electrophoresis deposition in absolute alcohol medium

A codeposition of bioglass (BG) and hydroxyapatite (HA) on the substrate Ti6Al4V is realized in a nonaqueous solution system by inducing crystallization of HA on surface of the BG grain and electrophoresis deposition (EPD), and then a bioactive graded ceramic coating was obtained after sintering of the coating. This technique is a new method for making bioactive graded coating. The adhesive strength between the coating and the substrate reaches 18?MPa, and the better electrophoresis depositing parameters and optimal sintering procedure are obtained.

Bonding strength of graded anti-corrosive coatings of fluoroethylenepropylene (FEP)/polyphenylene sulfide (PPS)

Fluororesin-based anti-corrosive coatings including graded FEP/PPS were prepared on carbon steel by melt powder coating, the bonding strength of all coating systems was determined by the pull-off test. It is found that the poor adhesion of fluororesin coatings to metallic substrates is improved obviously by the graded coating structure of FEP/PPS, and the bonding strength reaches up to 11.8 MPa for the five-layer system. Examination by electron probe microanalysis （EPMA） verifies that the distribution of main components is graded in the five-layer system, which is responsible for the enhancement of the interfacial bonding.

Characterization of functionally graded ZrO_2 thermal barrier coatings sprayed by supersonic plasma spray with dual powder feed ports

The functionally graded thermal barrier coatings （FG-TBCs） with 80%ZrO2-13%CeO2-7%Y2O3 （C-YSZ）/NiCoCrAlY were prepared using a recently developed supersonic plasma spraying（S-PS） with dual powder feed ports system. The thermal shock experiment of FG-TBCs specimens was carried out by means of the automatic thermal cycle device, in which the samples were heated to 1200℃ by oxygen-acetylene flame jet then water-quenched to ambient temperature. The temperature—time curves of specimens and photographs can be watched on-line and recorded by a computer during the test. The results show that the totally 1mm-thick FG-TBCs have excellent thermal shock resistance due to the fact that the coatings have no any peeling-off after 200 thermal cycles. The microstructures and morphologies of FG-TBCs were characterized and analyzed by SEM.

A facile method for fabrication of nano-structured Ni-Al_2O_3 graded coatings: Structural characterization

Powder charges of micron-size Ni and Al2O3were utilized to deposit nano-structured Ni-Al2O3composite coatings on analuminum plate fixed at the top end of a milling vial using a planetary ball mill.Composite coatings were fabricated using powdermixtures with a wide range of Ni/Al2O3mass ratio varying from1:1to plain Ni.XRD,SEM and TEM techniques were employed tostudy the structural characteristics of the coatings.It was found that the composition of the starting mixture strongly affects the Al2O3content and the microstructure of the final coating.Mixtures containing higher contents of Al2O3yield higher volume fractions of theAl2O3particles in the coating.Though Ni-Al2O3composite coatings with about50%of Al2O3particles were successfully deposited,well-compacted and free of cracks and/or voids coatings included less than20%(volume fraction)of Al2O3particles which weredeposited from powder mixtures with Ni/Al2O3mass ratios of4:1or higher.Moreover,mechanical and metallurgical bondings arethe main mechanisms of the adhesion of the coating to the Al substrate.Finally,functionally graded composite coatings withnoticeable compaction and integrity were produced by deposition of two separate layers under identical coating conditions.

Characterization of Failure Mechanisms of Duplex and Graded Thermal Barrier Coatings Exposed to Thermal Shock Test

The beginning of failure of a (ZrO2-7%Y2O3)/(Ni-22%Co-17%Cr-12.5%Al-0.6%Y) duplex andgraded coating systems on lnconel 617 and IN738LC in burner rig tests has been characterized.The test conditions are 40 s heating up to 75O℃ substrate temperature followed by 80 s aircooling. Failure is considered at the appearance of the first bright spot during heating period.Stresses due to thermal expansion mismatch strains on cooling are the probable cause of life-limiting in this conditions of testing.

Design of wideband graded-index antireflection coatings at oblique light incidence

We suggest a design method of graded-refractive-index （GRIN） antireflection （AR） coating for s-polarized or p- polarized light at off-normal incidence. The spectrum characteristic of the designed antireflection coating with a quintic effective refractive-index profile for a given state of polarization has been discussed. In addition, the genetic algorithm was used to optimize the refractive index profile of the GRIN antireflection for reducing the mean reflectance of s- and p-polarizations. The average reflectance loss was reduced to only 0.04% by applying optimized GRIN AR coatings onto BK7 glass over the wavelength range from 400 to 800 nm at the incident angle of θo = 70°.

Graded index broadband antireflection coating prepared by glancing angle deposition for a high-power laser system

This paper reports that SiO2 is selected to fabricate broadband antireflection （AR） coatings on fused silica substrate by using glancing angle deposition and physical vapour deposition. Through accurate control of the graded index of the SiO2 layer, transmittance of thc graded broadband AR coating can achieve an average value of 98% across a spectral range of 300-1850 nm. Moreover, a laser-induced damage threshold measurement of the fabricated AR coating is performed by using a one-on-one protocol according to ISOl1254-1, resulting in an average damage threshold of 17.2 J/cm2.

Thermal residual stress analysis of diamond coating on graded cemented carbides

Finite element model was developed to analyze thermal residual stress distribution of diamond coating on graded and homogeneous substrates. Graded cemented carbides were formed by carburizing pretreatment to reduce the cobalt content in the surface layer and improve adhesion of diamond coating. The numerical calculation results show that the surface compressive stress of diamond coating is 950 MPa for graded substrate and l 250 MPa for homogenous substrate, the thermal residual stress decreases by around 24% due to diamond coating. Carburizing pretreatment is good for diamond nucleation rate, and can increase the interface strength between diamond coating and substrate.

Fabrication of ZrO_2/Mo-Si/Ni Functionally Graded Material by Dip-Coating

A slurry dip-coating technique was developed for fabrication of Zr02/Mo-Si/Ni functionally graded material (FGM)on the stainless steel substrate. The rheological behavior of ZrO2-Ni-ethanol slurry was characterized by viscositytest. The amount of polyvinyl butyral (PVB) additives, which served as the dispersant and binder in ZrO2-Ni-ethanolslurry, was optimized. The results showed that the characters of mixed slurries with added 9 vol. pct (relativelyto total powders) MoSi2 powders prepared by mechanical alloying changed little. The stainless steel substrate wascoated several times by dipping in the slurries, and followed by drying in air every dipping. After debinding in Arin graphite die, the coated FGM plate was finally hot pressed at 1300℃ for 1 h under the pressure of 5 MPa in Arin the same die. Microstructural observations of the sintered FGM specimens revealed that the graded layers wereformed on the stainless steel substrate, in which no cracks were observed.

High-temperature tribological performance of functionally graded Stellite 6/WC metal matrix composite coatings manufactured by laser-directed energy deposition

Wear-driven tool failure is one of the main hurdles in the industry.This issue can be addressed through surface coating with ceramic-reinforced metal matrix composites.However,the maximum ceramic content is limited by cracking.In this work,the tribological behaviour of the functionally graded WC-ceramic-particlereinforced Stellite 6 coatings is studied.To that end,the wear resistance at room temperature and 400°C is investigated.Moreover,the tribological analysis is supported by crack sensitivity and hardness evaluation,which is of utmost importance in the processing of composite materials with ceramic-particle-reinforcement.Results indicate that functionally graded materials can be employed to increase the maximum admissible WC content,hence improving the tribological behaviour,most notably at high temperatures.Additionally,a shift from abrasive to oxidative wear is observed in high-temperature wear testing.

FORMATION OF GRADIENT COATING OF Fe-BASED ALLOY WITH RARE EARTHS BY PLASMA SURFACING

A gradient coating of Fe-based alloy was manufactured with rare earths (RE) by plasma surfacing on Q235 steel substrate. The coatings were studied by using X-ray diffraction(XRD), scanning electron microscope(SEM), differential thermal analyzer(DTA), and electron probe micro-analyzer (EPMA). The results show that the phases of the two kinds of coatings(with and without RE) both include α-Fe, Fe7C3, Fe3C, Cr2B, Fe2B and FeB. The microstructure of F314 coating is mainly hypereutectic, the pro-phases Cr7C3 and Cr2B are loose, crassi, spiculate and contain microcracks. The brittleness of the coating is high, and the average hardness is 787 HV. When 0.8wt% RE was added into the F314 alloy, the microstructure varied from hypoeutectic to hypereutectic continuously, The hardness appears as gradient distribution with the highest value of 773 HV, meanwhile, the brittleness decreases significantly. The formation of gradient structure depends on the fallowing factors: (i) the conversion of RE. The addition of RE lowers the elements point and Fe-C eutectic temperature, thus the base metal melting acutely. (ii) the heating of plasma arc. Graded temperature results in directional solidification, thus the gradient structure forms easily. The main reasons for the hardness decrease with RE addition in the alloy are the ratio of hard phase lowering and the hardness of the hard phase decreasing.

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.

Co-electrodeposition and properties evaluation of functionally gradient nickel coated ZrO_2 composite coating

For the first time,functionally electroless nickel plated ZrO2(NCZ)graded Ni-NCZ composite coating has been successfully co-electrodeposited from a bath with gradually increasing of stirring rate.Studies showed that co-electrodeposition in a bath with stirring rate of250r/min results in the maximum co-electrodeposited particle content and the best particle distribution.To produce NCZ graded Ni-NCZ composite coating,the stirring rate was continuously increased from0to250r/min.The electroplated coating had a continuous gradient increasing of co-electrodeposited NCZ content from substrate towards the surface.The results showed that with increasing the co-electrodeposited NCZ particles content in Ni matrix,microhardness increases from interface towards the surface of the coating.Little crystallite size of Ni matrix and higher co-electrodeposited hard particles content were recognized as the reasons of microhardness increasing.Bend test revealed that the functionally graded composite coating shows more excellent adhesion to the substrate compared with the ordinary distributed Ni-NCZ on the same substrate.This result is attributed to lower mechanical mismatch between coating and substrate in the functionally graded composite coating with respect to the uniformly distributed one.The results of wear resistance measurements reveal that wear resistance of functionally graded Ni-NCZ is higher than that of ordinary distributed composite coating.

Thermal Residual Stresses in Multilayered Coatings

The mechanical integrity and reliability of coated devices are strongly affected by the residual stresses in thin films and coatings. However, due to the metallurgical complexity of materials, it is rather difficult to obtain a closed-form solution of residual stresses within multilayered coatings （e.g. functionally graded coatings, FGCs）. In this paper,an analytical model is developed to predict the distribution of residual stresses within multilayered coatings. The advantage of this model is that the solution of residual stresses is independent of the number of layers. Specific results are obtained by calculating elastic thermal stresses in ZrO2/NiCoCrAIY FGCs, which consist of different material layers. Furthermore, the residual stress distribution near the edges and the stress-induced failure modes of coating are also analyzed. The topics discussed provide some insights into the development of a methodology for designing fail-safe coating systems.

Study of Co-Ce coating and surface on pasted nickel electrodes substrate

The process of electroplating Co-Ce alloys on the nickel foam framework surface can improve electro-conductivity for active materials and nickel substrate interface. The results of inductive coupled plasma emission spectrometer (ICP), cyclic voltammetry (CV), scanning electron microscopy (SEM), X-ray diffraction (XRD) and electron probe microanalysis (EPMA) indicate that the Co-Ce coating chemical content of rare earth Ce 0.19wt.%-0.28wt.% can not only alter the microstructure of electroplating coating, but also accelerate the oxidation reaction of Co and improve its transfer rate of electric current conductivity to the active material particles. The grads-like distributing electro-conductive network of CoOOH is formed on the nickel substrate surface, which improves reversibility of pasted nickel electrode. The charging receptivity is improved by Co-Ce coating on the pasted nickel electrode substrate, and its specific discharging capacity is improved by 50%.

Influence of the Thermal Barrier Coatings Design on the Oxidation Behavior

The properties of two different types of thermal barrier coatings （TBCs） were compared to improve the surface characteristics on high temperature components. These TBCs consisted of a duplex TBC and a five-layered functionally graded TBC. NiCrAIY bond coats were deposited on a number of Inconel-738LC specimens using high velocity oxy-fuel spraying （HVOF） technique. For duplex coating, a group of these specimens were coated with yttria stabilized zirconia （YSZ） using plasma spray technique. Functionally graded NiCrAIY/YSZ coatings were fabricated by plasma spray using co-injection of the two different powders in a single plasma torch. The amount of zirconia in functionally graded coatings were gradually increased from 30 to 100 vol. pct. Microstructural changes, thermally grown oxide （TGO） layer growth and damage initiation of the coatings were investigated as a function of isothermal oxidation test at 970℃. As a complementary test, the performance of the fabricated coatings by the optimum processing conditions was evaluated as a function of intense thermal cycling test at 1100℃. Also the strength of the adhesive coatings of the substrate was also measured. Microstructural characterization was analyzed by scanning electron microscopy （SEM） and optical microscopy whereas phase analysis and chemical composition changes of the coatings and oxides formed during the tests were studied by XRD （X-ray diffraction） and EDS （energy dispersive spectrometer）. The results showed that microstructure and compositions gradually varied in the functionally graded coatings. By comparison of duplex and functionally graded TBCs oxidation behavior （duplex failure after 1700 h and funcitionally graded TECs failure after 2000 h）, thermal shock test and adhesion strength of the coatings, the functionally graded TBC had better performance and more durability.