Title: Plasma spray ceramic coating and measurement of developed coating behaviour

Authors: M.S.A. Rahim, S. Nor Hayati, H. Luay Bakir

Addresses: Advanced Materials Centre, SIRIM Berhad, No 1 Persiaran Dato' Menteri, P.O. Box 7035, Shah Alam, Selangor 40911, Malaysia. ' Advanced Materials Centre, SIRIM Berhad, No 1 Persiaran Dato' Menteri, P.O. Box 7035, Shah Alam, Selangor 40911, Malaysia. ' School of Materials and Minerals Resources Engineering, USM, Engineering Campus, Nibong Tebal, Penang 14300, Malaysia

Abstract: Plasma spraying is the most flexible or versatile thermal spray processes. The high temperature of the plasma flame permits the coatings deposition for applying any ceramic materials such as chromium, titania, zirconia, alumina and its mixture. In general, this paper highlights the coating behaviour and performance of ceramic coating with different selection process parameters. This paper presents the development of ceramic coating using Al2O3 3%wt TiO2 material mostly used for wear application in industry. The coating is sprayed or developed using Praxair Plasma Spray system. In this coating, nickel base powder is applied as a bond coat material. Few important machine and process parameters, which have been established for production of coating such as powder flow rate, stand-off-distance of the spray gun also are discussed. The microstructure result and the phase of the spray coating is analysed and presented. In addition, the physical properties such as hardness, adhesion strength and wear behaviour of the sprayed coating are evaluated for final coating performance.

Keywords: plasma spraying; ceramics coatings; wear behaviour; process parameters; coating behaviour; microstructure; hardness; adhesion strength; coating performance.

DOI: 10.1504/IJPTECH.2009.026375

International Journal of Precision Technology, 2009 Vol.1 No.2, pp.163 - 172

Available online: 08 Jun 2009 *

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