Improving wear resistance of plasma-sprayed calcia and magnesia-stabilized zirconia mixed coating: roles of phase stability and microstructure

Abstract The phase stability and microstructure of ZrO2–5CaO and ZrO2–24MgO mixed coating (wt%) by air plasma spraying on 304 stainless steel substrates were investigated. A Ni–5Al (wt%) metallic bond coating was firstly sprayed between the substrate and the ceramic top layer. The results were compa...

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Autores principales:	Mohamed Abd-Elsattar Hafez, Sameh Ahmed Akila, Mohamed Atta Khedr, Ali Saeid Khalil
Formato:	article
Lenguaje:	EN
Publicado:	Nature Portfolio 2020
Materias:	Medicine R Science Q
Acceso en línea:	https://doaj.org/article/4160b2fdc4b14b788bfb1ac12bfb2666
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spelling	oai:doaj.org-article:4160b2fdc4b14b788bfb1ac12bfb26662021-12-02T12:33:04ZImproving wear resistance of plasma-sprayed calcia and magnesia-stabilized zirconia mixed coating: roles of phase stability and microstructure10.1038/s41598-020-78088-62045-2322https://doaj.org/article/4160b2fdc4b14b788bfb1ac12bfb26662020-12-01T00:00:00Zhttps://doi.org/10.1038/s41598-020-78088-6https://doaj.org/toc/2045-2322Abstract The phase stability and microstructure of ZrO2–5CaO and ZrO2–24MgO mixed coating (wt%) by air plasma spraying on 304 stainless steel substrates were investigated. A Ni–5Al (wt%) metallic bond coating was firstly sprayed between the substrate and the ceramic top layer. The results were compared with the individual coatings of ZrO2–5CaO and ZrO2–24MgO for a better understanding of the correlation between their microstructures and mechanical properties. Mixed zirconia coating was found to have a mixture of cubic and tetragonal phases that stabilized under different plasma spray conditions. Microscopic observations and elemental composition analysis of as-sprayed mixed coating showed that modified ceramic-matrix grains had been formed. Microsized ZrO2–5CaO particles were embedded in the matrix grain creating an intragranular microstructure. Results indicated that ceramic-matrix grains provided a diffusion barrier for the growth of oxides induced stress near and onto the bond layer that reduced cracks, thereby overcoming the top delamination of the ceramic coating. Moreover, disparity in wear resistance and microhardness behavior of the coatings was influenced by initial feedstock powder and matrix microstructures. Improvement in the wear resistance of the mixed zirconia coating was attributed to a decrease in oxide content, which resulted in an increase in intersplat cohesive strength.Mohamed Abd-Elsattar HafezSameh Ahmed AkilaMohamed Atta KhedrAli Saeid KhalilNature PortfolioarticleMedicineRScienceQENScientific Reports, Vol 10, Iss 1, Pp 1-14 (2020)
institution	DOAJ
collection	DOAJ
language	EN
topic	Medicine R Science Q
spellingShingle	Medicine R Science Q Mohamed Abd-Elsattar Hafez Sameh Ahmed Akila Mohamed Atta Khedr Ali Saeid Khalil Improving wear resistance of plasma-sprayed calcia and magnesia-stabilized zirconia mixed coating: roles of phase stability and microstructure
description	Abstract The phase stability and microstructure of ZrO2–5CaO and ZrO2–24MgO mixed coating (wt%) by air plasma spraying on 304 stainless steel substrates were investigated. A Ni–5Al (wt%) metallic bond coating was firstly sprayed between the substrate and the ceramic top layer. The results were compared with the individual coatings of ZrO2–5CaO and ZrO2–24MgO for a better understanding of the correlation between their microstructures and mechanical properties. Mixed zirconia coating was found to have a mixture of cubic and tetragonal phases that stabilized under different plasma spray conditions. Microscopic observations and elemental composition analysis of as-sprayed mixed coating showed that modified ceramic-matrix grains had been formed. Microsized ZrO2–5CaO particles were embedded in the matrix grain creating an intragranular microstructure. Results indicated that ceramic-matrix grains provided a diffusion barrier for the growth of oxides induced stress near and onto the bond layer that reduced cracks, thereby overcoming the top delamination of the ceramic coating. Moreover, disparity in wear resistance and microhardness behavior of the coatings was influenced by initial feedstock powder and matrix microstructures. Improvement in the wear resistance of the mixed zirconia coating was attributed to a decrease in oxide content, which resulted in an increase in intersplat cohesive strength.
format	article
author	Mohamed Abd-Elsattar Hafez Sameh Ahmed Akila Mohamed Atta Khedr Ali Saeid Khalil
author_facet	Mohamed Abd-Elsattar Hafez Sameh Ahmed Akila Mohamed Atta Khedr Ali Saeid Khalil
author_sort	Mohamed Abd-Elsattar Hafez
title	Improving wear resistance of plasma-sprayed calcia and magnesia-stabilized zirconia mixed coating: roles of phase stability and microstructure
title_short	Improving wear resistance of plasma-sprayed calcia and magnesia-stabilized zirconia mixed coating: roles of phase stability and microstructure
title_full	Improving wear resistance of plasma-sprayed calcia and magnesia-stabilized zirconia mixed coating: roles of phase stability and microstructure
title_fullStr	Improving wear resistance of plasma-sprayed calcia and magnesia-stabilized zirconia mixed coating: roles of phase stability and microstructure
title_full_unstemmed	Improving wear resistance of plasma-sprayed calcia and magnesia-stabilized zirconia mixed coating: roles of phase stability and microstructure
title_sort	improving wear resistance of plasma-sprayed calcia and magnesia-stabilized zirconia mixed coating: roles of phase stability and microstructure
publisher	Nature Portfolio
publishDate	2020
url	https://doaj.org/article/4160b2fdc4b14b788bfb1ac12bfb2666
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Improving wear resistance of plasma-sprayed calcia and magnesia-stabilized zirconia mixed coating: roles of phase stability and microstructure

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