Mining tailings as a raw material for glass-bonded thermally sprayed ceramic coatings: Microstructure and properties

Marjaana Karhu (Corresponding Author), Juha Lagerbom, Mari Honkanen, Elina Huttunen-Saarivirta, Jarkko Kiilakoski, Petri Vuoristo, Soili Solismaa, Päivi Kivikytö-Reponen

Research output: Contribution to journalArticleScientificpeer-review

4 Citations (Scopus)


Magnesium aluminate, MgAl2O4, spinel powders for thermal spraying, were synthesized from secondary raw materials by spray drying and subsequent reaction sintering. Talc ore mining tailings and aluminium hydroxide precipitate from aluminium anodizing process were studied. A stoichiometric MgAl2O4 spinel coating was prepared as a reference using pure raw materials. Atmospheric plasma spraying resulted in the formation of ceramic coatings. Microstructural investigations revealed that the reference coatings exhibited crystalline lamellar microstructure of MgAl2O4 but secondary coatings contained amorphous areas between the crystalline MgAl2O4 clusters. Abrasive wear test results revealed considerably lower wear rate for secondary coatings. It is suggested that the different structure of coatings, particularly the high degree of amorphous phase between the isolated crystalline MgAl2O4 clusters caused the higher abrasive wear resistance by changing the wear mechanism. The dielectric breakdown strength of the secondary coatings were at the same level, 24 V/μm, as compared to reference coating, 23 V/μm.

Original languageEnglish
Pages (from-to)4111-4121
JournalJournal of the European Ceramic Society
Issue number12
Publication statusPublished - Sept 2020
MoE publication typeA1 Journal article-refereed


The research has been supported by the Academy of Finland, project CeraTail funding decision # 292563 and by the Strategic Research Council at the Academy of Finland, project CloseLoop, funding decision #303453.


  • Ceramic coating
  • Circular economy
  • MgAlO spinel
  • Mining tailings
  • Thermal spray


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