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Role of lamellae morphology on the microstructural development and mechanical properties of small-particle plasma-sprayed alumina

Trice, Rodney W. and Faber, K. T. (2000) Role of lamellae morphology on the microstructural development and mechanical properties of small-particle plasma-sprayed alumina. Journal of the American Ceramic Society, 83 (4). pp. 889-896. ISSN 0002-7820. doi:10.1111/j.1151-2916.2000.tb01290.x.

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The influence of spray parameters on the microstructure and flexural strength of plasma-sprayed alumina was investigated. Coatings were applied using a small-particle plasma spray (SPPS) method, which is a recently patented process that allows submicrometer-sized powders to be sprayed. Using identical starting powders, coatings that were produced using two distinctly different spray conditions exhibited significant differences in both microstructure and strength. Scanning electron microscopy investigations of single lamellae (or splats) revealed that, for one spray condition, melted alumina particles will splash when they contact the substrate. The morphology of the splats that comprised the subsequent layers of the coating also were highly fragmented and thinner than lamellae formed under “nonsplashing” spray conditions. The surface roughness was strongly dependent on the morphology of the lamellae; increased roughness was noted for fragmented splats. Thick coatings that were comprised of splashed splats developed a unique microstructural feature that was responsible for the observed increase in roughness. These microstructural differences greatly influenced the flexure strength, which varied from 75 ± 21 MPa for the nonsplashing spray condition to 17 ± 2.4 MPa for the “splashing” condition.

Item Type:Article
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Faber, K. T.0000-0001-6585-2536
Additional Information:© 2000 The American Ceramic Society. Manuscript No. 189647. Received January 4, 1999; approved September 2, 1999. Supported by the “Environmentally Compliant Coatings for Wear and Corrosion Control” program of the U.S. Air Force Office of Scientific Research, under Contract No. F49620-96-1-0298. The authors wish to thank Rick Marzec for preparing the plasma-sprayed coatings. Tom Easley, Don Baskin, Jennifer Mawdsley, Jennifer Su, and Dr. Tom Bernecki, who also provided valuable input to this manuscript, are acknowledged.
Funding AgencyGrant Number
Air Force Office of Scientific Research (AFOSR)F49620-96-1-0298
Issue or Number:4
Record Number:CaltechAUTHORS:20140908-181324112
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Official Citation:Trice, R. W. and Faber, K. T. (2000), Role of Lamellae Morphology on the Microstructural Development and Mechanical Properties of Small-Particle Plasma-Sprayed Alumina. Journal of the American Ceramic Society, 83: 889–896. doi: 10.1111/j.1151-2916.2000.tb01290.x
Usage Policy:No commercial reproduction, distribution, display or performance rights in this work are provided.
ID Code:49399
Deposited By: George Porter
Deposited On:09 Sep 2014 20:25
Last Modified:10 Nov 2021 18:43

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