A new hybrid suspension and solution precursor thermal spray for wear-resistant silicon carbide composite coatings

Memon, Halar; Rincón Romero, Acacio; Derelizade, Kerem; Venturi, Federico; Hussain, Tanvir

Abstract

Silicon Carbide (SiC) coatings offer exceptional wear resistance and excellent tribological characteristics; however, it is a challenging material to be thermally sprayed due to a lack of melting point. In this study, a hybrid, single-step suspension and solution precursor feedstock design is proposed, consisting of a SiC suspension modified with Yttrium Aluminium Garnet (YAG) precursors, for thermal spraying of SiC/YAG coatings. The decomposition of SiC was restricted in all spray campaigns. The solid loading of SiC (from 10 wt% to 20 wt%) and YAG phase (from 20 wt% and up to 50 wt%) were varied in an attempt to improve wear performance, enhance coating cohesion, and minimise porosity of the studied coatings. Among all studied coatings, 60 wt% SiC/40 wt% YAG and 50 wt% SiC/50 wt% YAG coatings at a 10 wt% solid loading were the best-performing coatings, demonstrating a promising wear resistance up to a sliding distance up of 1000 m, a dense coating structure with porosity at 0.4 ± 0.2%. The feedstock design opens up a new method to process materials which are difficult, if not impossible, to process using a conventional thermal route.

Citation

Memon, H., Rincón Romero, A., Derelizade, K., Venturi, F., & Hussain, T. (2022). A new hybrid suspension and solution precursor thermal spray for wear-resistant silicon carbide composite coatings. Materials and Design, 224, Article 111382. https://doi.org/10.1016/j.matdes.2022.111382

• Journal Article Type: Article
• Acceptance Date: Nov 15, 2022
• Online Publication Date: Nov 17, 2022
• Publication Date: Dec 1, 2022
• Deposit Date: Mar 31, 2023
• Publicly Available Date: Apr 6, 2023
• Journal: Materials and Design
• Print ISSN: 0261-3069
• Electronic ISSN: 1873-4197
• Peer Reviewed: Peer Reviewed
• Volume: 224
• Article Number: 111382
• DOI: https://doi.org/10.1016/j.matdes.2022.111382
• Keywords: Mechanical Engineering, Mechanics of Materials, General Materials Science
• Public URL: https://nottingham-repository.worktribe.com/output/15924157
• Publisher URL: https://www.sciencedirect.com/science/article/pii/S0264127522010048?via%3Dihub