Review of Functionally Graded Thermal Sprayed Coatings

The paper briefly describes major thermal spray techniques used to spray functionally graded coatings such as atmospheric plasma spraying, high velocity oxy-fuel spraying, suspension and solution precursor plasma spraying, and finally low and high pressure cold gas spray method. The examples of combined spray processes as well as some examples of post spray treatment including laser and high temperature treatments or mechanical one, are described. Then, the solid and liquid feedstocks used to spray and their properties are shortly discussed. The reviewed properties of functional coatings include: (i) mechanical (adhesion, toughness, hardness); (ii) physical (porosity, thermal conductivity and diffusivity, thermal expansion, photo-catalytic activity), and; (iii) bioactivity and simulated body fluid (SBF) corrosion. These properties are useful in present applications of functionally graded coatings as thermal barriers, the bioactive coatings in prostheses, photo-catalytic coatings in water treatment, coatings used in printing industry (anilox and corona rolls). Finally, some of the future possible fields of functional thermal sprayed coatings applications are discussed, e.g., to coat polymer substrates or to use the cheap technology of low pressure cold gas spray method instead of expensive technology of vacuum plasma spraying to obtain bond coatings.

Microstructure and Mechanical Properties of Vacuum Plasma Sprayed HfC, TiC, and HfC/TiC Ultra-High-Temperature Ceramic Coatings

To improve the oxidation resistance of carbon composites at high temperatures, hafnium carbide (HfC) and titanium carbide (TiC) ultra-high-temperature ceramic coatings were deposited using vacuum plasma spraying. Single-layer HfC and TiC coatings and multilayer HfC/TiC coatings were fabricated and compared. The microstructure and composition of the fabricated coatings were analyzed using field-emission scanning electron microscopy and energy dispersive X-ray spectroscopy. The coating thicknesses of the HfC and TiC single-layer coatings were 165 µm and 140 µm, respectively, while the thicknesses of the HfC and TiC layers in the HfC/TiC multi-layer coating were 40 µm and 50 µm, respectively. No oxides were observed in any of the coating layers. The porosity was analyzed from cross-sectional images of the coating layers obtained using optical microscopy. Five random areas for each coating layer specimen were analyzed, and average porosity values of approximately 16.8% for the HfC coating and 22.5% for the TiC coating were determined. Furthermore, the mechanical properties of the coating layers were investigated by measuring the hardness of the cross section and surface roughness. The hardness values of the HfC and TiC coatings were 1650.7 HV and 753.6 HV, respectively. The hardness values of the HfC and TiC layers in the multilayer sample were 1563.5 HV and 1059.2 HV, respectively. The roughness values were 5.71 µm for the HfC coating, 4.30 µm for the TiC coating, and 3.32 µm for the HfC/TiC coating.

A COMPARATIVE STUDY ON VACUUM AND ATMOSPHERIC PLASMA SPRAYED TANTALUM COATINGS FOR THE MODIFICATION OF TITANIUM IMPLANTS

In order to improve the mechanical compatibility and cytocompatibility of titanium implants, tantalum coatings were prepared using plasma spraying technology. Tantalum coatings have been deposited via atmospheric plasama spraying (APS) and vacuum plasma spraying (VPS) methods, and then their morphologies, porosities, bonding strengths and elastic modulous were investigated. In vitro cytocompatibility of the two coatings was evaluated via human bone marrow stromal cells (hBMSCs). The results show that oxidation phenomenon was observed for the APS tantalum coatings, while less oxidation was found in the VPS tantalum coatings. Compared with APS tantalum coatings, the VPS tantalum coatings have a more compact microstructure and less impurity content, resulting in a better bonding with the titanium substrate. VPS tantalum coatings were measured to have a lower elastic modulus and a higher hardness than APS Tantalum coatings. Electrochemical corrosion of the coatings were examined and the VPS tantalum coating showed improved chemical stability. Besides, bone marrow stem cells (BMSCs) adhere to and spread well on the surface of both VPS and APS tantalum coatings without significant difference. The proliferation rate of BMSCs is higher on VPS tantalum coating surface than on APS tantalum coatings. Our results suggest that VPS tantalum coatings are more suitable for the application of surface modification of titanium implant due to their lower elastic modulus and better chemical stability for higher mechanical compatibility and cytocompatibility.

Oxidation Resistance of ZrB2-SiC-WSi2 Coating Prepared by Vacuum Plasma Spraying

ZrB2-SiC-WSi2 (labeled as ZSW) coating and ZrB2-SiC (labeled as ZS) coating were fabricated by vacuum plasma spray technique. The microstructure and composition of as-sprayed coating were detected through X-ray diffraction (XRD), scanning electron microscope (SEM) and X-ray energy dispersive spectrometry (EDS). Oxidation behaviors and microstructure evolution of these coatings were evaluated at 1500 °C in air and compared with ZrB2-SiC coating. The results showed that the addition of WSi2 improved the oxidation resistance of the ZrB2-SiC coating. There was more liquid formed on the ZSW coating surface. Some bubbles were also observed on the coating surface, which might be resulted from gas formation. It can be concluded that the amount of WSi2 had great influence on its function in ZrB2-SiC system.