Microstructure and oxidation resistance of reactive plasma clad Cr_7C_3/γ-Fe ceramic composite coating

A new type oxidation resistance in situ Cr7 C3/γ-Fe ceramic composite coating was fabricated on hardened and tempered grade C steel by reactive plasma clad with Fe-Cr-C alloy powders. The oxidation resistance of the ceramic composite coating was investigated under the test condition of 900 ℃ and 50 hours. The results indicate that the coating has a rapidly solidified microstructure consisting of blocky primary Cr7 C3 and the inter-blocky Cr7 C3/γ-Fe eutectics and is metallurgically bonded to the hardened and tempered grade C steel substrate. The high temperature oxidation resistance of the coating is up to 1.9 times higher than that of grade C steel. The oxidation kinetics curve of the coating is conforming to the parabolic-rate law equation. The excellent oxidation resistance of the coating is mainly attributed to the continuous oxide films which consist of Cr203 and Fe203. The continuous oxide films can prevent the inner part of the coating from being further oxidized.

Ceramic-Metal Composite Coating by Laser Cladding

Four kinds of ceramics (silicon carbide, boron carbide, aluminum oxide and tungsten carbide) were added into Ni base self-fluxing alloy as reinforcing materials in order to obtain metalceramic composite coating by means of laser cladding. A lot of experiments have been carried out to test the processability of the four kinds of ceramics with different sizes and contents. The microstructures of sintered tungsten carbide (S-WC) and cast tungsten carbide (C-WC) reinforced Ni base alloy coatings were analysed, the distortion regulation of laser clad specimens was revealed. The wear resistance of the composite coating has been tested.

Fabrication of in-situ synthesized ceramic reinforced Ni-based alloy composite coatings by reactive braze coating processing

In-situ synthesized ceramic such as TiC,Cr7C3 and Cr5B3 reinforced Ni-based alloy composite coating was fabricated on the surface of mild steel substrate by reactive braze coating processing with colloidal graphite,Cr,Ni,ferro-boron,Si and titanium powders as the raw materials at low temperature of 1000℃,and a new kind of coating materials was developed.By means of SEM,EDS,XRD and surface hardness tester,the microstructures,phases,hardness and wear-resistance of the coating were analyzed,respectively.The results revealed that the coating was mainly composed of the ceramic in-situ synthesized reinforcement phases of TiC,Cr7C3 and Cr5B3 and the binder phases in-situ synthesized of Ni31Si12 and(Ni,Fe)solid solution;The ceramic reinforcement phases of TiC,Cr7C3 and Cr5B3 were randomly distributed in the binder phases of Ni31Si12 and(Ni,Fe)solid solution;The coating had about 15vol%pores and can possibly be applied as a self-lubrication coating;The coating and the substrate were integrated together by metallurgical bonding;The coating had a hardness up to 91-94HR15N.

Residual Thermal Stresses of Laser Cladding of Intermetallic-Ceramic Composite Coatings

The stresses in laser cladding of Ni3Al-WC composite coating co and in heat affect zone (HAZ) σh have been induced based on considering the influences of laser processing parameters power P and beam traverse speed v.According to the calculated results, certain limits of P and v are necessary in order to obtain crack free coatings. It agrees well with the experimental results.

A method for preparing composite diffusion coating alloy on ceramic surface

Metallization of the ceramic surfaces of Si3N4 and Al2O3 was carried out in a composite diffusion coating vacuum furnace using a Ti-Cu composite target. The experimental process and influencing factors were discussed. Optical microscope （OM） , energy dispersive spectroscopy （EDS） , scanning electron microscopy （SEM） , X-ray diffusion （XRD） and sound emissive scratch test （SEST） were applied to evaluate the alloy layer formed on the ceramic surface. It was indicated that the diffusion coating alloy layer contained Cu, Ti, Fe, Al and Si etc. XRD result indicated that the diffusion coating alloy layer was composed of CuTi2, Cu, Si2 Ti and CuTi, Al2 TiO5 , Ti3O5. It was found that the diffusion coating alloy layer got bonded with ceramic well, and no spaUation occurred under the maximum load of 100 N. Deposited Si3N4 ceramic was welded with Q235 and the joining quality was examined. Robust joint was formed between Si3N4 ceramic/Q235. This present method has advantages in high efficiency and low cost and provides a new approach for producing ceramic and metal bond.

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.

Microstructure and Corrosion Resistance of Cr_7C_3/γ-Fe Ceramal Composite Coating Fabricated by Plasma Cladding

A new type in situ Cr7C3/γ-Fe ceramal composite coating was fabricated on substrate of hardened and tempered grade C steel by plasma cladding with Fe-Cr-C alloy powders. The ceramal composite coating has a rapidly solidified microstructure consisting of primary Cr7C3/γ- and the Cr7C3/γ-Fe eutectics, and is metallurgically bonded to the degree C steel substrate. The corrosion resistances of the coating in water solutions of 0.5 mol/L H2SO4 and 3.5% NaCl were evaluated utilizing the electrochemical polarization corrosion-test method. Because of the inherent excellent corrosion-resisting properties of the constituting phase and the rapidly solidified homogeneous microstructure, the plasma clad ceramal composite coating exhibits excellent corrosion resistance in the water solutions of 0.5 mol/L H2SO4 and 3.5% NaCl.

Formation and structure of composite coating of HDA and micro-plasma oxidation on A3 steel

Composite coatings were obtained on A3 steel by hot dipping aluminum(HDA) at 720 ℃ for 6 min and micro-plasma oxidation(MPO) in alkali electrolyte. The surface morphology, element distribution and interface structure of composite coatings were studied by means of XRD, SEM and EDS. The results show that the composite coatings obtained through HDA/MPO on A3 steel consist of four layers. From the surface to the substrate, the layer is loose Al2O3 ceramic, compact Al2O3 ceramic, Al and FeAl intermetallic compound layer in turn. The adhesions among all the layers are strengthened because the ceramic layer formed at the Al surface originally, FeAl intermetallic compound layer and substrate are combined in metallurgical form through mutual diffusion during HDA process.Initial experiment results disclose that the anti-corrosion performance and wear resistance of composite coating are obviously improved through HDA/MPO treatment.

Effect of Al_2O_3on Structure and Wearability of Composite Coating

The composite coating was prepared by thermal spray welding after making composite powder,which is composed of Ni-based self-melted alloy and AlOceramic powder including nano,sub-micron and micron powders.The influences of contents and sizes of AlOon the structure and wearability were investigated.The results show that the wear resistance of the coating would be increased greatly by adding AlO,but the spray weldability decreases with increasing AlOcontent.So there is an optimal content of AlOpowder.The composite coating with AlOnano or sub-micron powder of 0.5% has the best abrasive resistance,while the optimal content of AlOmicron powder is 1 %.

Compound Ceramic Coatings Grown by Micro-plasma Oxidation on Ti-6Al-4V Alloy

Compound ceramics coatings on the Ti-6Al-4V alloy were prepared by the direct current micro-plasma oxidation （MPO） in NaAlO2 solution. The composition and morphology of the coatings were studied with the X-ray diffraction （XRD） and the scanning electron microscopy （SEM）, respectively. Inductively coupled plasma atomic emission spectrometer technique was used to analyze the solution features of Ti-6Al-4V alloy in the process of preparation. The results reveal that Al2TiO5 forms in the coatings at the initial stages of MPO reaction, and its content changes rapidly with the reaction continuing： after 20 min, the ceramics coatings are composed of α-Al2O3, 7-Al2O3 and Al2TiO5, but after 40 min, its main composition is of α-Al2O3. The content of Ti in the solution will increase when the MPO time extends, and as will Al in the anode area until, after 30 min, it reaches the maximum and keeps constant from then on. Both substrata of Ti and Al in the electrolyte join the MPO reaction at the initial stage, where the formation of Al2TiO5 happens; but as the MPO reaction prolongs, more and more Al in the electrolyte will take part in the reaction, leading to the appearance of a large amount ofAl2O3.

Composite ceramics thermal barrier coatings of yttria stabilized zirconia for aero-engines

Composite ceramics thermal barrier coatings(TBCs) are widely used in the aero-engines field due to their excellent thermal insulation, which improves the service life and durability of the inherent hot components. The most typical, successful and widely used TBCs material is yttria stabilized zirconia(YSZ). In this paper, fabrication methods, coating structures, materials, failure mechanism and major challenges of YSZ TBCs are introduced and reviewed. The research tendency is put forward as well. This review provides a good understanding of the YSZ TBCs and inspires researchers to discover versatile ideas to improve the TBCs systems.

Advances in ultra-high temperature ceramics,composites,and coatings

Ultra-high temperature ceramics(UHTCs)are generally referred to the carbides,nitrides,and borides of the transition metals,with the Group IVB compounds(Zr&Hf)and TaC as the main focus.The UHTCs are endowed with ultra-high melting points,excellent mechanical properties,and ablation resistance at elevated temperatures.These unique combinations of properties make them promising materials for extremely environmental structural applications in rocket and hypersonic vehicles,particularly nozzles,leading edges,and engine components,etc.In addition to bulk UHTCs,UHTC coatings and fiber reinforced UHTC composites are extensively developed and applied to avoid the intrinsic brittleness and poor thermal shock resistance of bulk ceramics.Recently,high-entropy UHTCs are developed rapidly and attract a lot of attention as an emerging direction for ultra-high temperature materials.This review presents the state of the art of processing approaches,microstructure design and properties of UHTCs from bulk materials to composites and coatings,as well as the future directions.

Microstructural evolution and abrasive resistance of WC7Co ceramic particle-reinforced Ti6Al4V composite coating prepared by pulse laser cladding

WC7Co/Ti6Al4V composite coatings are deposited on the pure Ti substrate by pulse laser cladding(LC).During the laser melting process,the decomposition of WC7Co particles will lead to the evolution of microstructure and phases,which is directly related to the wear resistance and mechanism of composite coating.The microstructural evolution,phase compositions and interface reaction of WC7Co/Ti6Al4V composite coating were examined by scanning electron microscopy,energydispersive spectrum and X-ray diffraction(XRD).The hardness of different structures and abrasive resistance of composite coating were measured.The results show that the typical microstructure of LC WC7Co/Ti6Al4V composite coating can be classified into dissolved WC7Co composite structure and un-dissolved WC7Co structure.According to XRD results,there are Ti solid solution,W,TiC,VC,Co3W3C and secondary W2C in composite coating.The eutectic structure formed by the dissolved WC7Co particles consisted of W,W2C,TiC and P-Ti solid solution.The mean hardness of different structures exhibits a significant gradient distribution in composite coating.A reaction layer composed of TiC,W and W2C is also generated onto the interface between un-dissolved WC7Co particles and Ti6Al4V alloy matrix.The abrasive mechanisms of WC7Co/Ti6Al4V composite coating are mainly adhesive wear and oxidation wear during the dry sliding process.

Fabrication and characterization copper/diamond composites for heat sink application using powder metallurgy

Copper composites reinforced with diamond particles were fabricated by the powder metallurgical technique. Copper matrix and diamond powders were mixed mechanically, cold com- pacted at 100 bar then sintered at 900?C. The prepared powders and sintered copper/diamond composites were investigated using X-ray diffraction (XRD) and scanning electron microscope equipped with an energy dispersive X-ray analysis (SEM/EDS). The effect of diamond contents in the Cu/diamond composite on the different properties of the composite was studied. On fracture surfaces of the Cu/uncoated diamond composites, it was found that there is a very weak bonding between diamonds and pure copper matrix. In order to improve the bonding strength between copper and the reinforcement, diamond particles were electroless coated with NiWB alloy. The results show that coated diamond particles distribute uniformly in copper composite and the interface between diamond particles and Cu matrix is clear and well bonded due to the formation of a thin layer from WB2, Ni3B, and BC2 between Cu and diamond interfaces. The properties of the composites materials using coated powder, such as hardness, transverse rupture strength, thermal conductivity, and coefficient of thermal expansion (CTE) were exhibit greater values than that of the composites using uncoated diamond powder. Additionally, the results reveals that the maximum diamond incorporation was attained at 20 Vf%. Actually, Cu/20 Vf% coated diamond com- posite yields a high thermal conductivity of 430 W/mK along with a low coefficient of thermal expansion (CTE) 6 × 10–6/K.

Effect of magnesium and nickel coatings on the wetting behavior of alumina toughened zirconia by molten Al-Mg alloy

The wettability of alumina toughened zirconia （ZTA） by Al-Mg alloy was investigated using the sessile drop technique. The ef fects of nickel coating, magnesium content, nitrogen atmosphere, and processing temperature on the contact angle between the molten alloy and the substrate were determined. Likewise, the effect of these factors on the wetting properties was studied. The results showed that the nickel coating on the ceramic substrate caused a significant reduction in solid/liquid surface energy and the contact angle decreased obvi- ously. The presence of magnesium in the molten aluminum alloy in nitrogen atmosphere reduced the contact angle effectively. The presence of magnesium in the alloy must be at a minimum amount of 2wt%-3wt% . Moreover, it was suggested that some chemical reactions in the Al-Mg-N system led to the production of Mg3N2 and AlN compositions. These compositions improved the wetting properties of the systems by reducing the surface energy of the molten. It was shown that increasing the temperature is also an effective factor for the enhancement of wetting properties.

Study on the subsonic speed flame spraying coating of hydroxyapatite

A new method of preparation of biomaterial composite coating by the techniqueof subsonic thermal spraying was discussed in this paper. Ti_6Al_4V and pure Ti were chosen assubstrate and sublayer material respectively and the working layer was sprayed with biomaterialhydroxyapatite (HAP), forming the composite coating. The experiments of heat shock and tensilestrength showed that the bonding strength between coating and substrate is almost as same as that ofspecimen in which Ni/Al powder was adopted as sublayer. The phases of TiN, TiO_2, and Ti_2O_3 wereformed in the sublayer, which are free of toxic and have no side effects. The powder of workinglayer HAP was decomposed partly during spraying, but it can be solved by later treatment.

CMC-EBC损伤耦合机理及一体化设计研究进展

陶瓷基复合材料与环境障碍涂层组合(CMC-EBC)是目前航空航天领域最具应用前景的热结构材料体系。本文对CMC-EBC失效机理与分析模型的研究进展进行综述。首先,简要回顾了CMC-EBC材料体系的发展及主要制备工艺。然后,综述了CMC-EBC在服役环境下的主要损伤模式与失效机理,总结发现CMC预制体结构、孔洞缺陷和EBC内裂纹等损伤演化相互影响,这种细观损伤模式的耦合是决定其寿命的关键因素之一,但目前的机理研究主要集中于涂层本身性能及其受环境因素的影响,缺乏对涂层和复合材料编制结构在损伤演化过程中协同效应的考虑。接下来,详细分析了CMC-EBC的失效模拟与预测模型研究的历史与现状,指出其中存在的问题,包括环境因素建模方法和损伤耦合演化模拟技术。目前大部分工作致力于分别开发CMC和EBC的失效模型,而对于CMC-EBC构件的失效预测应考虑其损伤演化与微观结构之间的相互耦合影响。最后,对CMC-EBC材料体系研发与服役性能预测方法进行了展望,认为CMC本体和EBC失效模式相互耦合,开展结构功能一体化设计和分析是CMC-EBC构件研究的趋势。

大气等离子喷涂Si/Mullite+BSAS/Yb_(2)Si_(2)O_(7)环境障涂层的制备与水氧腐蚀行为

以固相烧结法制备的Yb_(2)Si_(2)O_(7)粉体作为原材料,采用大气等离子喷涂工艺在SiC基体表面制备Si/Mullite+BSAS/Yb_(2)Si_(2)O_(7)三层结构环境障涂层。利用扫描电子显微镜、能谱仪、X射线衍射分析仪、纳米压痕试验机等设备研究涂层的显微组织、相结构和力学性能。结果表明:粉体材料由83%Yb_(2)Si_(2)O_(7)相和17%Yb_(2)SiO_(5)相(质量分数)组成,等离子喷涂获得的Yb_(2)Si_(2)O_(7)层孔隙率为(6.61±0.65)%,涂层结合强度达(22.82±3.55)MPa,涂层断裂韧度达(1.98±0.12)MPa·m1/2。此外,涂层1350℃条件下水氧耦合腐蚀测试结果显示Yb_(2)Si_(2)O_(7)单斜相含量先降低后提高,硅黏结层高温氧化形成的热生长氧化物SiO_(2)与Mullite+BSAS界面相容,未发现Mullite+BSAS与Yb_(2)Si_(2)O_(7)层互扩散现象,硅层的损耗是涂层使用寿命的主要限制环节。

耐高温吸波陶瓷及其涂层的研究进展

随着近现代科技的发展,高速飞行器对生存能力需求不断提高,其鼻锥、机翼、尾喷管等高温部件极易暴露。传统吸波材料普遍不能应用于高温环境,为了能够隐藏高速飞行器的高温部件,吸波材料的高温应用引起了研究人员的重视,耐高温吸波陶瓷材料可以实现上述背景下的应用。为提供分析和改善陶瓷吸波材料高温程度有限和吸收带宽较窄问题的依据,对引入温度影响后,耐高温吸波陶瓷材料的吸波机理进行了阐述。耐高温吸波陶瓷材料与涂层可以分为碳化物陶瓷、氮化物陶瓷、氧化物陶瓷和聚合物转化陶瓷。本文在此分类的基础上,对陶瓷吸波材料和涂层损耗电磁波机理及其高温条件下的吸波性能进行了归纳总结,并指出未来耐高温吸波陶瓷材料应改善现有材料耐高温程度不足以及有效吸收带宽较窄的问题,进而加强其在高温条件下的服役能力。