Investigations on (ZrO2.5CaO+Al2O3) appliedon Al6061and Gray cast Iron (GCI) substrates

Abstract

Identifying the factual structure and mechanical properties plays a very important role before and after thermal spray coatings. This paper addresses best possible methods for the evaluation of Air plasma spray coatings on Al6061and Gray Cast Iron samples. In the present experimental work Alumina plus Calcia stabilized zirconia were used as a top coat, applied on both the samples and only one bond coat i.e.Fe38Ni10Al applied on Gray Cast Iron ,two bond coats namely Al25Fe7Cr5Ni-BC1 & Al20330 (Ni20Al)-BC2 applied on Al6061sustrate.In the study it was realized that a very good adhesion exist between substrates and bond coat and little deformities observed between top coat (ZrO2.5CaO+Al203 ) & bond coat 2 Al20330 (Ni20Al) in case of Al6061.A very Good bonding understood in case of GCI coating systems. A very unique mineral, Tarzhenite phase identified in XRD analysis and it was found that the hardness of the top coat is significantly affected by porosity and the specific weight percentage of Tarzhenite in the coating systems.