Influence of Feedstock and Thermal Spray Process on the Phase Composition of Alumina Coatings and Their Sliding Wear

Abstract

Suspension thermal spraying is an emerging coating technology that enables the deposition of dense-structured ceramic coatings. As wear resistance is a main application field of alumina (Al2O3) coatings, this study aimed to evaluate the dry reciprocating sliding wear resistance of suspension sprayed high velocity oxy-fuel (S-HVOF) alumina coatings and to compare it with atmospheric plasma sprayed (APS) and HVOF coatings. Coatings were analyzed in the as-sprayed state and post-treated at 910 °C (hot isostatically pressed, HIPed) conditions. Wear tests were conducted using a tribometer, following the ASTM G133-02 standard and a sintered WC-6 wt.% Co ball as the counterbody. Coating characterization was done using scanning electron microscopy, x-ray diffraction and nanoindentation technique.