Development of alumina-based hybrid composite coatings for high temperature erosive and corrosive environments

Gupta, Avi; Pattnayak, Abhijit; Abhijith, N.V.; Kumar, Deepak; Chaudhry, V.; Mohan, Sanjay

doi:10.1016/j.ceramint.2022.09.059

Cited by 20 publications

(6 citation statements)

References 44 publications

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“…It is a trade-off between deposition efficiency and coating density vis à vis the nozzle length and exit size; deposition efficiency drops with The top surface morphology of coatings reveals the makeup of a thermal spray coating. It shows the spread of deposited materials when molten [23,24], clusters of materials that may be partly molten, or materials retained from the sprayed feedstock [25]. The four coating samples (runs 1-4) show consistency in this regard; the top surface of each of the coatings presents mostly highly deformed materials.…”

Section: Microstructure: Materials and As-sprayed Coatingsmentioning

confidence: 98%

Microstructure and Tribological Performance of HVAF-Sprayed Ti-6Al-4V Coatings

Owoseni,

Ciudad de Lara,

Mathiyalagan

et al. 2023

Coatings

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Ti-6Al-4V is a widely used titanium alloy in aviation and bio/chemical applications for its attractive mechanical and corrosion resistance properties. The use of Ti-6Al-4V as a coating for repair purposes through thermal spray techniques provides a unique productivity opportunity. A repair coating must be dense to provide the required in-service functionalities, such as resistance to wear. The High Velocity Air Fuel (HVAF) thermal spray technique deposits dense coatings with reduced concern for oxide inclusions. This work presents an investigation of the microstructure, dry sliding, and solid particle erosive wear performance of four different coatings engineered through the configuration of the nozzle of an HVAF spray gun, based on the length of the nozzle and the size of the nozzle exit. A long nozzle length and wide nozzle exit mean increased inflight dwell time and reduced average inflight temperature for the sprayed particles, respectively—a reversed configuration means the opposite. The tested coatings showed a porosity of less than 2%. The sliding and erosion wear performance of the densest of the coatings compares to that of the bulk material tested under the same conditions. Electron microscopy was used to investigate the driving mechanisms for the performance of the respective coatings. The implications of the results are discussed for the potential adoption of HVAF-sprayed coatings in metal component repair.

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Section: Microstructure: Materials and As-sprayed Coatingsmentioning

confidence: 98%

Microstructure and Tribological Performance of HVAF-Sprayed Ti-6Al-4V Coatings

Owoseni,

Ciudad de Lara,

Mathiyalagan

et al. 2023

Coatings

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“…Fig. 3 Mechanism of formation of super alloy coatings [46] Super alloy coatings have exceptional high-temperature stability, since they possess the capacity to retain their structural integrity and mechanical capabilities even under increased temperature conditions that would often result in degradation for conventional materials, as shown in fig. 3.…”

Section: Real-world Applicationsmentioning

confidence: 99%

Super Alloy Coatings for Enhanced Corrosion and Oxidation Resistance in Extreme Environments

Abhishek,

Anupama,

Singh

et al. 2023

E3S Web Conf.

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The use of super alloy coatings is an innovative method for enhancing the durability of materials against the detrimental effects of corrosion and oxidation, especially in areas with severe circumstances. This study explores the forefront of super alloy coatings, examining their significant role in minimising the adverse effects of corrosive and oxidative processes on materials working in harsh conditions. This study highlights the transformative potential of super alloy coatings in extending the lifespan and enhancing the reliability of critical components. It achieves this by presenting a comprehensive overview of the fundamental principles, fabrication methodologies, and practical applications associated with these coatings. As many sectors navigate more difficult environments, the effective incorporation of advanced coatings presents a potential direction, advancing the field of materials science and guaranteeing consistent performance in the presence of significant challenges. The emergence of super alloy coatings represents a significant transformation in the field of corrosion and oxidation control, providing a robust defence against the persistent deteriorating factors seen in highly challenging settings. The combination of complex production procedures and superior material qualities empowers these coatings to strengthen materials, therefore assuring their durability.

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“…Water molecules can permeate the polymer superficial layer and cause volume swelling, resulting in structural instability, strength and hardness decrease, and wear increase [8]. Self-lubricating alumina ceramics have many excellent properties, such as high load bearing, wear resistance, high temperature resistance, and oxidation resistance [9,10]. Alumina ceramic-based self-lubricating materials can meet sealing requirements in harsh environments completely and do not increase the weight seriously [11].…”

Section: Introductionmentioning

confidence: 99%

Tribological Properties of Al2O3/Graphite-Al2O3 Laminated Composites under Water Lubrication Conditions

Di,

Wang,

Zhang

et al. 2024

Lubricants

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High-performance Al2O3/graphite-Al2O3 laminated composites exhibit an excellent self-lubricating ability for moving components, such as sliding shaft sleeves and dynamic seals. The tribological behaviors of Al2O3/graphite-Al2O3 laminated composites should be studied extensively under water working conditions. Here, we attempted to explore the practicability of the Al2O3/graphite-Al2O3 laminated composite as a sealing material from a tribological point of view under water lubrication conditions. The tribological properties and mechanism of friction and wear of laminated composite ceramics were investigated under dry sliding friction, water environment, and suspended particle working conditions. It was found that the Al2O3/graphite-Al2O3 laminated composite has a better friction performance under water lubrication compared to dry sliding because of the separation effects formed by a water molecule film and a transfer film. Meanwhile, the wear rate under dry contact was found to be approximately six times that under water lubrication conditions. Under the water lubrication conditions, the formation of graphite films and water-adsorbed layers improved the anti-wear properties of the laminated materials, and the friction coefficient and the wear rate were as low as 0.16 and 1.76 × 10−6 mm3/Nm, respectively. Under the suspended particle working condition, the solid particles destroyed the graphite lubricating film and abrasive wear dominated the wear mode. The Al2O3/graphite-Al2O3 laminated composite demonstrates a potential for application in dynamic sealing and sliding components.

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Development of alumina-based hybrid composite coatings for high temperature erosive and corrosive environments

Cited by 20 publications

References 44 publications

Microstructure and Tribological Performance of HVAF-Sprayed Ti-6Al-4V Coatings

Microstructure and Tribological Performance of HVAF-Sprayed Ti-6Al-4V Coatings

Super Alloy Coatings for Enhanced Corrosion and Oxidation Resistance in Extreme Environments

Tribological Properties of Al2O3/Graphite-Al2O3 Laminated Composites under Water Lubrication Conditions

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