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Fabrication and Characterization of Plasma-Sprayed Cr3C2-25 Cr/Al2O3-40TiO2 Duplex Coating

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Abstract

The atmospheric plasma spray process is considered here as a suitable techniques for fabricating ceramic coatings. The duplex coating system consists of two layers: Cr3C2-25NiCr (as bond coat) and Al2O3-40TiO2 (as top coat). Plasma spraying parameters including spraying distance (100-200 mm), powder feed rate (10–50 g/min), and arc current (500–600 A) were used to fabricate this coating system on a S45C steel surface. The effect of plasma spraying parameters on coating properties and structure was evaluated. The experimental results showed that the optimal operating conditions provided the lowest value of coating porosity (~4%), corrosion current density icorr (~6.12 μA/cm2), HV0.1 microhardness (~846) at 10 g/min powder feed rate, 100 mm spraying distance, and 600 A current. The sample sprayed at 30 g/min powder feed rate, 150 mm spray distance, and 550 A arc current had the highest value of coating adhesion (~ 55 MPa). The results of X-ray diffraction analysis on the surface of the coating samples showed that most TiO2 crystals were dissolved in γ-Al2O3 to form a solid Al2TiO5 solution.

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Data Availability

The data used to support the findings of this study are available from the corresponding author upon request.

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Acknowledgments

The authors are grateful for financial support by the Vietnam National Foundation for Science and Technology Development (NAFOSTED, Grant 104.03-2019.21).

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Authors and Affiliations

  1. Institute for Tropical Technology, Vietnam Academy of Science and Technology, 18, Hoang Quoc Viet, Cau Giay, Hanoi, Vietnam

    Tuan Nguyen Van, Tuan Anh Nguyen, Ha Pham Thi, Ly Pham Thi & Phuong Nguyen Thi

  2. National Key Laboratory for Welding and Surface Treatment Technologies, NARIME, 4, Pham Van Dong, Cau Giay, Hanoi, Vietnam

    Quy Le Thu

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  1. Tuan Nguyen Van
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TNV: Conceptualization, project administration. TAN: Review and editing. HPT: Writing and editing. LPT: Formal analysis. PNT: Formal analysis. QLT: Investigation, review and editing.

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Van, T.N., Nguyen, T.A., Thi, H.P. et al. Fabrication and Characterization of Plasma-Sprayed Cr3C2-25 Cr/Al2O3-40TiO2 Duplex Coating. J Therm Spray Tech 31, 2112–2125 (2022). https://doi.org/10.1007/s11666-022-01423-y

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