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Transactions of JWRI, Vol.39 (2010), No. 1 Fig. 13 Microstructure of a zirconia coating. (a) gas tunnel type plasma spraying apparatus, (b) conventional plasma spraying apparatus. Zirconia coatings produced with the gas tunnel-type plasma spraying apparatus exhibit much less porosity. It is therefore obvious that the quality of the sprayed coatings is superior to that of conventionally produced coatings since the fewer the pores, the greater the homogeneity of the coating. As a result of the reduced porosity zirconia coatings have very high quality characteristics than other coating materials. 6.2.2 Alumina coating A high quality coating of alumina with a Vickers hardness of 1200 to 1600 HV have been obtained by gas tunnel plasma spraying 22) . The gas tunnel plasma spraying was used for an alumina coating formed at a short spray distance, and the coating characteristics were discussed 23) . The Vickers hardness of the cross section was measured for this alumina coating, and the effect of the spraying conditions (spraying distance, power input, etc.) on the properties of the alumina coating were also discussed. The microstructure of such alumina coated material was examined by optical microscopy shown in Fig. 15. There are differences in the coating microstructure indicated as A, B, and C in Fig. 15. Regions A and B correspond to the high hardness region in which the distance from the surface is less than 300 m and the Vickers hardness is more than 1000 HV. This coating region was formed during the second and third passes of the torch. In region B, the cell size is small compared to the other regions and forms a layer that is -60 m thick, which corresponds to the hardness >1300 HV. On the other hand, for region A near the coating surface, the cell size is greater. In this region, the hardness is a little lower than that in area B. Closest to the substrate, region C corresponds to the first torch pass. This region has the same coating structure as that formed by gas tunnel plasma spraying at the usual spraying distance. Region C is formed during the first traverse and consists of an upper dark layer that is -alumina rich and a lower layer near the substrate that is a bright, -alumina rich area. The brightness increases considerably on the coating over region C. Region B has a fine structure and is the brightest indicating that this layer has a high concentration of -alumina. Region A, near the surface and formed on the third pass of the torch, has the highest brightness and indicates a high concentration of -alumina. Regions under A are slightly darker and indicate a mixture of -alumina and -alumina phases. The ratio of -alumina and -alumina is nearly constant for the whole coating, which corresponds to the flat distribution of the Vickers hardness in the thickness direction. Fig. 15 Microstructure of a alumina coating. The thickness of this coating is about 450 m. Fig. 14 Microstructure of a alumina-titania coating. (a) gas tunnel type plasma spraying apparatus, (b) conventional plasma spraying apparatus. 17PDF Image | Carbon Dioxide Decomposition by Plasma Methods
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