Effect of the suspension composition on the microstructural properties of high velocity suspension flame sprayed (HVSFS) Al2O3 coatings

Seven different Al2O3-based suspensions were prepared by dispersing two nano-sized Al2O3 powders (having analogous size distribution and chemical composition but different surface chemistry), one micron-sized powder and their mixtures in a water+isopropanol solution. High velocity suspension flame sprayed (HVSFS) coatings were deposited using these suspensions as feedstock and adopting two different sets of spray parameters. The characteristics of the suspension, particularly its agglomeration behaviour, have a significant influence on the coating deposition mechanism and, hence, on its properties (microstructure, hardness, elastic modulus). Dense and very smooth (Ra ~ 1.3 μm) coatings, consisting of well- flattened lamellae having a homogeneous size distribution, are obtained when micron-sized (~1 -2 μm) powders with low tendency to agglomeration are employed. Spray parameters favouring the break-up of the few agglomerates present in the suspension enhance the deposition efficiency (up to >50%), as no particle or agglomerate larger than ~2.5 μm can be fully melted. Nano-sized powders, by contrast, generally form stronger agglomerates, which cannot be significantly disrupted by adjusting the spray parameters. If the chosen nanopowder forms small agglomerates (up to few microns), the deposition efficiency is satisfactory and the coating porosity is limited, although the lamellae generally have a wider size distribution, so that roughness is somewhat higher. If the nanopowder forms large agglomerates (on account of its surfacechemistry), poor deposition efficiencies and porous layers are obtained. Although suspensions containing the pure micron-sized powder produce the densest coatings, the highest deposition efficiency (~70%) is obtained by suitable mixtures of micron-and nano-sized powders, on account of synergistic effects