Impact of Plasma Spray Variables Parameters on Mechanical and Wear Behaviour of Plasma Sprayed Al2O3 3%wt TiO2 Coating in Abrasion and Erosion Application

AbstractAlumina-titania coatings produced by plasma spray processes are being developed for a wide variety of applications that require resistance to wear, erosion, cracking and spallation. Consideration of parameters setting will develop reliable coatings with high performance properties for demanding coating application. Al2O3 3%wt TiO2 coating was produced onto metal substrate using Praxair Plasma Spray System with SG-100 Gun. This paper discusses the experimental and testing performance analysis of the coating which prepared based on three varied process parameters (current, powder flow rate and stand-off-distance). With the varied coating parameters, test results showed that increasing current from 550A to 650A and powder flow rate from 22.5g/min to 26g/min increased the performance of mechanical properties of coating (adhesion strength & hardness) and gave the lowest friction coefficient value (i.e. best wear resistance) of coating. Increasing stand-off-distance from 75mm to 90mm also increased hardness performance and provided the lowest friction coefficient value of coating. However increasing stand-off-distance has decreased adhesion strength at setting powder flow rate of 26g/min and 650A current. The behavior of such parameters setting significantly influenced the production of optimum Al2O3 3%wt TiO2 coating onto metal substrate