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Composite coatings containing nanometric constituents prepared by plasma spraying with liquid feedstocks
Mušálek, Radek ; Tesař, Tomáš ; Medřický, Jan ; Čížek, Jan ; Lukáč, František
Plasma spraying of liquid feedstocks allows deposition of materials with novel microstructures. Due to the combination of a liquid carrier and ultrafine powders (in case of suspensions) or in-situ formation of the final material in the plasma jet (in case of solutions), preparation of ultrafine composites is possible, typically in a form of coatings on the substrates. Moreover, both suspension and solution spraying routes can be easily combined, either together or even with conventional plasma spraying of coarse dry powders, thus merging benefits of “nanometric” and “micrometric” constituents in the final composite microstructure. As a consequence, liquid feedstock plasma spraying represents an industrially-relevant deposition process with wide variability, providing coatings with properties tailored for various applications ranging from compact wear-resistant layers, porous thermal barrier coatings, bio-compatible medical coatings, catalyst carriers, fuel-cells, etc. The paper introduces several examples of such ultrafine coatings recently deposited at IPP CAS using hybrid water-stabilized plasma torch.
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Suspension plasma spraying of sub-stoichiometric titania by hybrid water/argon stabilized plasma torch
Mušálek, Radek ; Ctibor, Pavel ; Medřický, Jan ; Tesař, Tomáš ; Kotlan, Jiří ; Lukáč, František
In this study, suspension plasma spraying of sub-stoichiometric titania was attempted using hybrid water/argon stabilized plasma torch (WSP-H). Porous coatings with fine cauliflower-like columnar microstructure were successfully deposited in two separate experiments with different power levels of the plasma torch. In both cases, high solid-load content (40 wt. %) of the water-based suspension resulted in considerable coating thickness increase per deposition cycle. Coating annealing and partial remelting of the surface asperities were also achieved by additional pass of plasma torch in front of the coating surface. According to X-ray diffraction, all coatings consisted dominantly of rutile phase. Detailed microscopic observation of the as-sprayed and annealed deposits showed that the local coloration of the coating (ranging from dark blue to beige) was driven by the local overheating of the rough coating surface which could also promote the oxygen intake. Moreover, sample annealing was also observed to increase the sample reflectivity as observed by UV-VIS-NIR scanning spectrophotometry
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Deposition of Titania from Solution by Hybrid Water-Stabilized Plasma Torch
Mušálek, Radek ; Medřický, Jan ; Tesař, Tomáš ; Kotlan, Jiří ; Lukáč, František
Thermal spraying with liquid feedstock presents a novel route for deposition of functional coatings. In this study, possibility of preparation of titania coatings from solution by hybrid water stabilized plasma torch is presented. Coatings were prepared from solution of titanium isopropoxide Ti[OCH(CH3)2]4 in anhydrous ethanol. Fragmentation of feedstock stream in the plasma jet was monitored by shadowgraphy. Deposition was carried out on steel samples mounted to the cooled rotating carousel. Cross-sectional images from SEM microscope showed successful formation of the deposit with dual morphology consisting of fine feather-like features combined with bigger droplets. X-ray diffraction revealed formation of nanometric rutile crystallites.
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