Morphology and Mechanical Properties of a Composite Coating by Electrostatic Dry Spray Method

Abstract:

Powder spray coating was used for many applications such as paint decoration and protection against corrosive environments. The electrostatic spray method is used to lower the manufacturing cost and the environmental effect during the production process. It is done by electrostatic device and spray gun to create a layer on the substrate to play a protective role. Different dry powders were mixed to form a composite mixture consisted of Al2O3 and SiC or ZrSiO4 with Al powder as a binder. The powders mixture was deposited by electrostatic spray technique with a high voltage of 15 kV on a low carbon steel substrate of (40 x 10 x 4) mm in dimensions. Two groups of mixtures were used to form the coating layers. Powders of Al₂O₃ with (20 and 40) weight percent (wt%) of SiC as the first group and (20 and 40) wt% of ZrSiO4 as the second group were used. 5 wt% of Al powder was added as a binder, and the samples were heat treated at 900 C° for 2 hours. A detailed characterization of the composite coating layers was performed using XRD, SEM, and EDX, as well as, micro-hardness measurements. The obtained surface composite layers were smooth and having good particle distribution which leads to enhance roughness values (Ra). Furthermore, the hardness increased with increasing the amount of carbide and zirconia, and the obtained layers show no presence of defects or cracks.

• Periodical: Key Engineering Materials (Volume 886)
• Pages: 168-174
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.886.168
• Online since: May 2021
• Authors: Mohanad N. Al-Shroofy*, Hanna A. Al-Kaisy, Rabab Chalaby
• Keywords: Al₂O₃–SiC Coating, Al₂O₃–ZrSiO₄ Coating, Composite Coating, Electrostatic Coating Technique

References

[1] Kumar, S., Chakraborty, M., Sarma, V. S., & Murty, B.S. (2008). Tensile and wear behaviour of in situ Al–7Si/TiB2 particulate composites. Wear, 265(1-2), 134-142.

DOI: 10.1016/j.wear.2007.09.007

[2] Pai, B.C., Pillai, R. M., & Satyanarayana, K.G. (1993). Stir Cast Aluminium Alloy Matrix Composites. In Key Engineering Materials (Vol. 79, pp.117-128). Trans Tech Publications Ltd.

DOI: 10.4028/www.scientific.net/kem.79-80.117

[3] Baily A.G, (1998), the science and technology electrostatic powders spraying transport and coating", J. electrostatic, 45,85-120.

[4] Dinaharan, I. (2016). Influence of ceramic particulate type on microstructure and tensile strength of aluminum matrix composites produced using friction stir processing. Journal of Asian Ceramic Societies, 4(2), 209-218.

DOI: 10.1016/j.jascer.2016.04.002

[5] Taya, M., Hayashi, S., Kobayashi, A. S., & Yoon, H. S. (1990). Toughening of a Particulate‐Reinforced Ceramic‐Matrix Composite by Thermal Residual Stress. Journal of the American Ceramic Society, 73(5), 1382-1391.

DOI: 10.1111/j.1151-2916.1990.tb05209.x

[6] Al-Shroofy, M., Zhang, Q., Xu, J., Chen, T., Kaur, A. P., & Cheng, Y. T. (2017). Solvent-free dry powder coating process for low-cost manufacturing of LiNi1/3Mn1/3Co1/3O2 cathodes in lithium-ion batteries. Journal of Power Sources, 352, 187-193.

DOI: 10.1016/j.jpowsour.2017.03.131

[7] AL-Shroofy, M. N. (2017). Understanding and improving manufacturing processes for making lithium-ion battery electrodes.

[8] Trisaksri, V., & Wongwises, S. (2007). Critical review of heat transfer characteristics of nanofluids. Renewable and sustainable energy reviews, 11(3), 512-523.

DOI: 10.1016/j.rser.2005.01.010

[9] Mazumder, M. K., Wankum, D. L., Sims, R. A., Mountain, J. R., Chen, H., Pettit, P., & Chaser, T. (1997). Influence of powder properties on the performance of electrostatic coating process. Journal of electrostatics, 40, 369-374.

DOI: 10.1016/s0304-3886(97)00073-9

[10] Krella, A. K., Krupa, A., Sobczyk, A. T., & Jaworek, A. (2016). Al2O3+ TiO2 thin film made by electrostatic spray deposition. Advances in Materials Science, 16(3), 47-55.

DOI: 10.1515/adms-2016-0016

[11] Kallio, G. A., & Stock, D. E. (1986). Computation of electrical conditions inside wire‐duct electrostatic precipitators using a combined finite‐element, finite‐difference technique. Journal of Applied Physics, 59(6), 1799-1806.

DOI: 10.1063/1.336402

[12] Ye, Q., Steigleder, T., Scheibe, A., & Domnick, J. (2002). Numerical simulation of the electrostatic powder coating process with a corona spray gun. Journal of Electrostatics, 54(2), 189-205.

DOI: 10.1016/s0304-3886(01)00181-4

[13] Barletta, M., & Tagliaferri, V. (2006). Influence of process parameters in electrostatic fluidized bed coating. Surface and Coatings Technology, 200(14-15), 4619-4629.

DOI: 10.1016/j.surfcoat.2005.04.030

[14] Mohammed, M. A., Zaidan, S. A., & Smich, H. A. (2018, December). Near Net Shape Fabrication of Ceramic Composite Tube by Thermal Spray Forming. In IOP Conference Series: Materials Science and Engineering (Vol. 454, No. 1, p.012038). IOP Publishing.

DOI: 10.1088/1757-899x/454/1/012038