Understanding the formation mechanism of supersonic atmospheric plasma sprayed in-situ hypereutectic Al-25 wt%Si coating with nanostructured coupled eutectic: From powder, in-flight droplet, splat to coating

He, Pan; Tang, Ling; Guo, Ma; Wang, Haidou; Chen, Shuying; Liu, Ming; Ding, Shuyu; Bai, Yu; Tang, Jianjiang; He, Dongdong

doi:10.1016/j.apsusc.2020.147246

Cited by 16 publications

(11 citation statements)

References 55 publications

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“…22,23 Hence, this paper established the corresponding temperature field and temperature gradient according to the equipment parameters. 24 The vapor pressure obtained above can be used to calculate the capacity of gaseous material along the jet direction according to the Clapeyron-Clausius equation.…”

Section: Sublimation Calculation By Finite Element Analysismentioning

confidence: 99%

Deposition behavior and mechanism of thermal sprayed SiC

Liu,

Li,

Guo

et al. 2023

J Am Ceram Soc.

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It is widely known that silicon carbide (SiC) is challenging to thermal spray. However, the nature of deposition and the underlying mechanisms are still not clearly understood. In the current work, the process of atmospheric plasma‐sprayed SiC was investigated in detail. SiC exhibits sublimation severely under the plasma spraying (PS). More than 65 mol.% SiC particles lost by sublimation during PS estimated by calculation. Due to the nonuniformity of temperature in plasma flame, a small amount of SiC particles was retained. Moreover, a small amount of Si and SiO2 was experimentally observed after deposition process from the single‐splat characterization. According to the first‐principles calculations, the detachment energy of C atom from the lattice (0.591 eV) is lower than that of Si atom (1.257 eV). The adsorption energies of an O atom on the Si‐ and C‐terminated surfaces are −9.549 and −7.631 eV, respectively. Therefore, C is more likely to form gaseous products after decomposition, and Si is more likely to be retained to form Si and SiO2. Mullite was found on the grain boundaries of molten Si, which was attributed to the rapid diffusion of the Al2O3 substrate along the grain boundaries of Si, promoting the spreading of molten splats. It is difficult to stack particles through self‐diffusion among SiC particles to form coatings. The discovery on thermal deposition mechanism of SiC in PS is helpful to promote the practical application of SiC coatings on preparation optimization and interfacial bonding improvement.

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Section: Sublimation Calculation By Finite Element Analysismentioning

confidence: 99%

Deposition behavior and mechanism of thermal sprayed SiC

Liu,

Li,

Guo

et al. 2023

J Am Ceram Soc.

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“…Firstly, the droplets on the periphery of the plasma jet have a lower temperature and velocity, which made it difficult for the heat of the jet to transfer to the center of the powder and thereby result in the partial melt of some droplets with a larger particle size. The partially melted bulk silicon phases might disintegrate and fixed in the coating by the subsequent spreading of the droplets [26]. Secondly, when the latter droplet was In addition, the silicon phase in the Al-25Si-4Cu-0.9Mg powder exhibited a large size of 3 µm with a polygonal shape.…”

Section: Microstructure Of the Powder And Al-25si Coatingmentioning

confidence: 99%

“…Firstly, the droplets on the periphery of the plasma jet have a lower temperature and velocity, which made it difficult for the heat of the jet to transfer to the center of the powder and thereby result in the partial melt of some droplets with a larger particle size. The partially melted bulk silicon phases might disintegrate and fixed in the coating by the subsequent spreading of the droplets [26]. Secondly, when the latter droplet was deposited on the previously spread droplet during the spraying process, the local remelting might occur on the contact surface, thereby increasing the grain size of the nano-silicon particles to a certain extent, which made part of the featureless area transform to the fine-grained region.…”

Section: Microstructure Of the Powder And Al-25si Coatingmentioning

confidence: 99%

“…He [26] compared the Vickers hardness and Si phase size of Al-25Si coating prepared by SAPS with that of high-silicon aluminum alloy prepared by other rapid solidification technologies. He find that the inner hole Al-25Si coating prepared by the SAPS exhibited an average microhardness of 267.09 ± 14.85HV 0.2 , which is much higher than that of high-silicon aluminum alloys prepared by other rapid solidification techniques, including rapid solidification-powder metallurgy technology (RS-PM), the solidified alloy of spinquenched strips (MSRC), spray deposition and hot extrusion (SF(E)), selective laser melting technology (SLM), vacuum plasma spraying (VPS) and conventional casting process (CCP).…”

Section: Microhardness Of Inner Pore Al-25si Coatingmentioning

confidence: 99%

“…In addition, in the deposition process of SAPS, the internal stress generated by particle accumulation and dislocations during the fragmentation and splashing between particles would be beneficial to the enhancement of the coating strength. Meanwhile, the inert gas protection could also prevent the oxidation of aluminum alloys [26]. Therefore, the inner hole SAPS is expected to prepare the high silicon aluminum coating on the inner surface of the aluminum alloy cylinder with a certain strength and wear resistance [27][28][29].…”

Section: Introductionmentioning

confidence: 99%

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Microstructure, Phase Composition, Mechanical Properties and Tribological Properties of Plasma Sprayed Al-25Si Wear-Resistant Coatings

Peng¹,

Liu²,

Huang³

et al. 2022

Surfaces

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Owing to the light weight and high energy, the “All-aluminum engine” can reduce fuel consumption and pollutant emissions, showing a great significance in saving resources and protecting the environment, and becoming a research hotspot. However, the aluminum alloy cylinder liners have difficulty withstanding extremely harsh working conditions, such as strong friction and wear, making the engine extremely easy to damage. In this work, Al-25Si wear-resistant coating was deposited by inner hole supersonic plasma spraying technique to improve the wear resistance of the aluminum alloy cylinder liner. The microstructure, phase composition, mechanical properties and tribological properties were tested by SEM, XRD, tribological machine, etc. The results indicated that the coating exhibited an excellent bonding strength of 44.1 MPa, and the average hardness and average friction coefficient of the coating are 267.09 ± 14.85 HV0.2, and 0.20, respectively. The total wear amount, the wear scar width and the wear scar depth of the coating are 2.77 × 10−3 mm3, 654.3 μm and 8.95 μm, respectively, which showed that the coating can significantly improve the tribological properties of the “All-aluminum engine”. The wear mechanism of the coating was mainly interpreted by furrow cutting, extrusion and spalling in two-body abrasive wear, three-body abrasive wear and a small amount of oxidative wear.

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