Investigation of Ceramic Coating by Thermal Spray with Diffusion of Copper

M. Mohammeda, Sh. Zaidana, H. Smichb aDepartment of Applied Sciences, University of Technology, Baghdad, Iraq bDepartment of Materials Engineering, University of Technology, Baghdad, Iraq

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Flame thermal spray techniques were used to prepare composites of ceramic powders, alumina and silica (Al2O3+SiO2), zirconia with titanium (TiO2+ ZrSiO4) and zirconia with alumina (Al2O3+ZrSiO4) by weight percentages (5%, 10%, 15%, 20%), to study the performance of composites coating on the diffusion of copper during the sintering process at a temperature (1500°) for two hours. Result of energy dispersive X-ray test showed that the higher value of the diffusion copper was in alumina brick substrate without coating 46.11%, while ceramic coating specimens of SiO2 with Al2O3 , Al2O3 and TiO2 with ZrSiO4 made barrier to reduce the diffused atoms of copper especially of SiO2 with Al2O3 and Al2O3 with ZrSiO4 specimens; this led to improving the mechanical properties. Scanning electron microscopy and atomic force microscope test showed that the dense ceramic coating structures are more organized and homogeneous with absence of large pores or voids especially after copper diffusion inside bricks within ceramic coating. Greatest adhesion strength 5.46 MPa of the coating layer with the alumina brick substrate, it was achieved by zircon silicate with 20% α-Al2O3 (with higher alumina ratio) and zircon silicate with 20% TiO2 which has lower value of adhesive bonding strength (3.352 MPa).

DOI:10.12693/APhysPolA.134.248 topics: spray forming, alumina + 5%MgO, alumina + 28%SiO2, AFM