On the role of particle state and deposition procedure on mechanical, tribological and dielectric response of high velocity oxy-fuel sprayed alumina coatings

Erja Turunen (Corresponding Author), Tommi Varis, Simo-Pekka Hannula, A. Vaidya, A. Kulkarni, S. Gutleber, S. Sampath, H. Herman

Research output: Contribution to journalArticleScientificpeer-review

50 Citations (Scopus)

Abstract

It is well known that the high velocity oxy-fuel based thermal spray process impart high density and reduced porosity in coatings compared to those produced by other ambient thermal spray processes. The benefits of HVOF have largely remained in the domain of metals and cermets and limited investigations have been carried out in ceramic coatings. The ability to produce high density ceramic coatings (e.g. alumina) offers potential in high performance applications in the field of wear, corrosion resistance, and dielectric coatings. However, due to extreme operational limits of the HVOF process, the fundamentals of process-structure-property relationships are not fully understood. In this paper, we report an integrated approach to establish processing-microstructure-property correlations in order to optimize coatings for such applications. This approach involves diagnostic studies, microstructure development and its resultant influence on properties of high velocity oxy-fuel (HVOF) sprayed alumina coatings. The diagnostic studies were aimed to investigate the effects of fuel gas/oxygen ratio and amount of total gas flow on the particle temperature and velocity. Furthermore, splats and coatings were deposited to investigate the relationship between diagnostic data, melting behavior and droplet substrate interactions. Such a comprehensive study, coupled with property measurements of the coatings, demonstrates critical operational variables among deposition procedure, coating microstructure and the deposit properties.
Original languageEnglish
Pages (from-to)1-11
JournalMaterials Science & Engineering A: Structural Materials: Properties, Microstructure and Processing
Volume415
Issue number1-2
DOIs
Publication statusPublished - 2006
MoE publication typeA1 Journal article-refereed

Fingerprint

Aluminum Oxide
Alumina
aluminum oxides
coatings
Coatings
ceramic coatings
Ceramic coatings
microstructure
Microstructure
sprayers
cermets
Cermets
Gas fuels
corrosion resistance
Density (specific gravity)
gas flow
Flow of gases
Corrosion resistance
Melting
Deposits

Keywords

  • thermal spray
  • HVOF
  • process optimization
  • diagnostic
  • alumina
  • mechanical properties
  • thermal and electrical properties
  • ProperPart

Cite this

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title = "On the role of particle state and deposition procedure on mechanical, tribological and dielectric response of high velocity oxy-fuel sprayed alumina coatings",
abstract = "It is well known that the high velocity oxy-fuel based thermal spray process impart high density and reduced porosity in coatings compared to those produced by other ambient thermal spray processes. The benefits of HVOF have largely remained in the domain of metals and cermets and limited investigations have been carried out in ceramic coatings. The ability to produce high density ceramic coatings (e.g. alumina) offers potential in high performance applications in the field of wear, corrosion resistance, and dielectric coatings. However, due to extreme operational limits of the HVOF process, the fundamentals of process-structure-property relationships are not fully understood. In this paper, we report an integrated approach to establish processing-microstructure-property correlations in order to optimize coatings for such applications. This approach involves diagnostic studies, microstructure development and its resultant influence on properties of high velocity oxy-fuel (HVOF) sprayed alumina coatings. The diagnostic studies were aimed to investigate the effects of fuel gas/oxygen ratio and amount of total gas flow on the particle temperature and velocity. Furthermore, splats and coatings were deposited to investigate the relationship between diagnostic data, melting behavior and droplet substrate interactions. Such a comprehensive study, coupled with property measurements of the coatings, demonstrates critical operational variables among deposition procedure, coating microstructure and the deposit properties.",
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author = "Erja Turunen and Tommi Varis and Simo-Pekka Hannula and A. Vaidya and A. Kulkarni and S. Gutleber and S. Sampath and H. Herman",
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On the role of particle state and deposition procedure on mechanical, tribological and dielectric response of high velocity oxy-fuel sprayed alumina coatings. / Turunen, Erja (Corresponding Author); Varis, Tommi; Hannula, Simo-Pekka; Vaidya, A.; Kulkarni, A.; Gutleber, S.; Sampath, S.; Herman, H.

In: Materials Science & Engineering A: Structural Materials: Properties, Microstructure and Processing, Vol. 415, No. 1-2, 2006, p. 1-11.

Research output: Contribution to journalArticleScientificpeer-review

TY - JOUR

T1 - On the role of particle state and deposition procedure on mechanical, tribological and dielectric response of high velocity oxy-fuel sprayed alumina coatings

AU - Turunen, Erja

AU - Varis, Tommi

AU - Hannula, Simo-Pekka

AU - Vaidya, A.

AU - Kulkarni, A.

AU - Gutleber, S.

AU - Sampath, S.

AU - Herman, H.

N1 - Project code: G3SU00865

PY - 2006

Y1 - 2006

N2 - It is well known that the high velocity oxy-fuel based thermal spray process impart high density and reduced porosity in coatings compared to those produced by other ambient thermal spray processes. The benefits of HVOF have largely remained in the domain of metals and cermets and limited investigations have been carried out in ceramic coatings. The ability to produce high density ceramic coatings (e.g. alumina) offers potential in high performance applications in the field of wear, corrosion resistance, and dielectric coatings. However, due to extreme operational limits of the HVOF process, the fundamentals of process-structure-property relationships are not fully understood. In this paper, we report an integrated approach to establish processing-microstructure-property correlations in order to optimize coatings for such applications. This approach involves diagnostic studies, microstructure development and its resultant influence on properties of high velocity oxy-fuel (HVOF) sprayed alumina coatings. The diagnostic studies were aimed to investigate the effects of fuel gas/oxygen ratio and amount of total gas flow on the particle temperature and velocity. Furthermore, splats and coatings were deposited to investigate the relationship between diagnostic data, melting behavior and droplet substrate interactions. Such a comprehensive study, coupled with property measurements of the coatings, demonstrates critical operational variables among deposition procedure, coating microstructure and the deposit properties.

AB - It is well known that the high velocity oxy-fuel based thermal spray process impart high density and reduced porosity in coatings compared to those produced by other ambient thermal spray processes. The benefits of HVOF have largely remained in the domain of metals and cermets and limited investigations have been carried out in ceramic coatings. The ability to produce high density ceramic coatings (e.g. alumina) offers potential in high performance applications in the field of wear, corrosion resistance, and dielectric coatings. However, due to extreme operational limits of the HVOF process, the fundamentals of process-structure-property relationships are not fully understood. In this paper, we report an integrated approach to establish processing-microstructure-property correlations in order to optimize coatings for such applications. This approach involves diagnostic studies, microstructure development and its resultant influence on properties of high velocity oxy-fuel (HVOF) sprayed alumina coatings. The diagnostic studies were aimed to investigate the effects of fuel gas/oxygen ratio and amount of total gas flow on the particle temperature and velocity. Furthermore, splats and coatings were deposited to investigate the relationship between diagnostic data, melting behavior and droplet substrate interactions. Such a comprehensive study, coupled with property measurements of the coatings, demonstrates critical operational variables among deposition procedure, coating microstructure and the deposit properties.

KW - thermal spray

KW - HVOF

KW - process optimization

KW - diagnostic

KW - alumina

KW - mechanical properties

KW - thermal and electrical properties

KW - ProperPart

U2 - 10.1016/j.msea.2005.08.226

DO - 10.1016/j.msea.2005.08.226

M3 - Article

VL - 415

SP - 1

EP - 11

JO - Materials Science & Engineering A: Structural Materials: Properties, Microstructure and Processing

JF - Materials Science & Engineering A: Structural Materials: Properties, Microstructure and Processing

SN - 0921-5093

IS - 1-2

ER -