Linear Reciprocating Wear of Yttria-Stabilized Zirconia-Based Composite Coatings Developed by Thermal Spray
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JMEPEG https://doi.org/10.1007/s11665-020-05039-7
Linear Reciprocating Wear of Yttria-Stabilized Zirconia-Based Composite Coatings Developed by Thermal Spray Subhasisa Nath
, Indranil Manna, Jonathan Lawrence, and Jyotsna Dutta Majumdar
(Submitted April 15, 2020; in revised form August 3, 2020) Ceramic matrix composites are the preferred material for high-temperature application due to their low density, improved strength and toughness, and high-temperature capabilities. In the present study, we report the kinetics and mechanism of linear reciprocating wear of yttria-stabilized zirconia (YSZ)-based composite coatings developed by thermal spray technique. Composite coatings with different volume fractions of CoNiCrAlY and YSZ phases were subjected to linear reciprocating wear under an applied normal load of 10 N against a WC counter-body. The kinetics of wear was investigated by measuring the wear depth over time of coated components against WC surface. Adhesive wear in the 100% CoNiCrAlY coating was responsible for increased friction in the coating which changed to a three-body abrasion in the case of 100% YSZ coating. The composition coatings had a significant effect on the wear mechanism with the ceramic coatings were fractured under reciprocating load. Microcrack propagation and fracturing of ceramic splats were the dominant modes of wear in the ceramic coatings. The 100% YSZ coating showed significant wear than 100% CoNiCrAlY and 50% YSZ + 50% CoNiCrAlY coatings. The mode of wear changed with the presence of a metallic phase in the 50% YSZ + 50% CoNiCrAlY coating. The mode of wear was further studied by the detailed microstructural observation of worn track and correlating it with the wear kinetics and coefficient of friction. Keywords
CMCs, coating, hardness, linear reciprocating wear, thermal spray
1. Introduction Oxide ceramics are drawing attention in the manufacturing industries owing to their high hardness, chemical inertness, low thermal conductivity, etc. (Ref 1). However, these ceramic materials have inferior strength and poor toughness (Ref 1, 2). Among the oxide ceramics, yttria-stabilized zirconia (YSZ) and alumina (Al2O3) possess many technological advantages over other ceramics due to high hardness, high strength, superior fracture toughness, excellent wear resistance, high chemical and corrosion resistance, and excellent biocompatibility (Ref 36). The loss of material due to wear and energy loss due to friction can be minimized by keeping the coefficient of friction as low as possible. Despite the widespread use of YSZ as a heat resistant material, it lacks the strength required to be used for wear resistant material such as in applications involving cutting tool and bio-implants (Ref 7-11). On the other hand, Al2O3 possesses the necessary hardness sought for the wear resistance application, but it underperforms due to inferior fracture Subhasisa Nath and Jonathan Lawrence, School of Mechanical, Aerospace and Automotive Engineering, Coventry University, Coventry CV1 2JH, UK; and Indranil Manna a
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