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Interfacial Microstructure and Bonding Properties of Plasma-Sprayed Multilayer Ceramic Coating (Al2O3/BaTiO3/Al2O3-40 wt.% TiO2)

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Abstract

In multilayer coatings, the bonding mechanisms between the different layers determine the cohesive strength of the coatings, which in turn to a large extent controls the mechanical properties of coatings under different loading conditions. In this study, the interfacial bonding state and adhesive strength of a plasma-sprayed single-layer coating (Al2O3), a double-layer coating (Al2O3/BaTiO3), and a three-layer coating (Al2O3/BaTiO3/Al2O3-40 wt.% TiO2) were investigated, as well as their phase composition and microstructure. Scanning electron microscopy observation showed that the microstructure of the three ceramic coatings was relatively dense with a good interface bonding state. However, micro-cracks were observed in the smooth region of the double-layer coating interface, while pores were observed at the BaTiO3/Al2O3-40 wt.% TiO2 interface in the three-layer coating. Transmission electron microscopy observation revealed that element diffusion occurred at the interface. The diffusion depth at the Al2O3/BaTiO3 and BaTiO3/Al2O3-40 wt.% TiO2 interfaces reached 12 nm and 10 nm, respectively. Therefore, both mechanical interlocking (the dominant mechanism) and limited chemical diffusion contributed to interface adhesion in the multilayer coatings. The adhesion strengths of the double-layer, single-layer, and three-layer coatings were 40.1, 21.8, and 15.3 MPa, respectively. The latter exhibited the lowest adhesion strength mainly because of the relatively weak Al2O3/BaTiO3 interface.

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Acknowledgments

The authors gratefully acknowledge the National Natural Science Foundation of China (Grant Nos. 51775554 and 51535011) and the National Security Major Basic Research Program of China (973 Program, Grant No. 613283) for the financial support. Furthermore, the authors thank Dr. Li Qiang and Dr. Ma Wen (ZHONG KE BAI CE, China) for the TEM analysis. Additionally, the ability to perform tensile experiments as provided by Xia Xi-gong (University of Science and Technology Beijing, China) is greatly appreciated.

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Authors and Affiliations

  1. National Key Lab for Remanufacturing, Army Academy of Armored Forces, Beijing, 100072, China

    Li Zhou, Zhi-guo Xing, Hai-dou Wang, Peng-fei He, Qing-bo Mi, Wei-ling Guo, Yan-fei Huang, Ling Tang, He-fa Zhu & Xian-yong Zhu

  2. Institute of Surface/Interface Science and Technology, Key Laboratory of Superlight Material and Surface Technology of Ministry of Education, College of Material Science and Chemical Engineering, Harbin Engineering University, Harbin, 150001, China

    Qing-bo Mi

  3. School of Engineering and Technology, China University of Geosciences, Beijing, 100083, China

    Ling Tang

  4. College of Mechanics and Power Engineering, China Three Gorges University, Yichang, 433000, China

    He-fa Zhu

  5. College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310014, China

    Xian-yong Zhu

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  1. Li Zhou
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Zhou, L., Xing, Zg., Wang, Hd. et al. Interfacial Microstructure and Bonding Properties of Plasma-Sprayed Multilayer Ceramic Coating (Al2O3/BaTiO3/Al2O3-40 wt.% TiO2). J Therm Spray Tech 29, 2012–2025 (2020). https://doi.org/10.1007/s11666-020-01097-4

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