Improving Mechanical Properties of Nanostructured Cr2O3 Plasma Sprayed Coating through formation of Cr2O3-20YSZ-10SiC Nanocomposite Coatings

Cr2O3, YSZ and SiC nano-powders were prepared by ball milling and subsequently mixed and agglomerated to reach the proper composition and size for spraying. Morphological investigations and particle size analysis showed that powder particles after 5h of milling time reached to an ultrafine/nano size. The powder mixtures were then deposited onto 304L steel substrates using Atmospheric Plasma Spray (APS) to deposit Cr2O3-20vol%YSZ-10vol%SiC composite coating. Microstructure and morphology of the elemental/milled powders and plasma sprayed coatings were characterized using Field Emission scanning electron microscopy (FESEM) equipped by EDS. X-ray diffraction (XRD) patterns of powder particles and coatings included only the elemental peaks without any traces of impurities and new appearance peaks. Using image analysis method, the coatings porosity content increased from 8.7 to 12.8 through formation of composite coating. Also mechanical properties of the coatings including bonding strength, micro hardness and fracture toughness were evaluated. The results showed that coatings have high bonding strength of 40-49 MPa. Regarding hardness and toughness results, adding reinforcements to Cr2O3 coating increased hardness and toughness to 910 HV and 8.1 MPam1/2, respectively.