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The Microstructure and Mechanical Properties of ZrO2-AlzO: Thick Film
Formed on the SUS304 Sheet Using Thermal Spray
Ken HIRota*, Xiaoteng Gn, Masaki Kano, Muhammad RraL Hiroluki MIYAMoTo
(Received September 7 ,2016)
AZrO2-Al2O3-based thick
film
has been formed on the SUS 304 stainless-steel sheet using a thermal spray
plasma spraying: APS). The chemical composition
of
in air (atmospheric
starting raw materiai (cttbrc ZrO2 solid solution: c-ZrO2(ss)) is
which has been prepared by the neutralization co-precipitation method followed by the
T5molYoZrO2(l.5mo1%Y2O3)-25molo/oAl2O3,
calcination of 1373 K( 1 100'C) for several hours in air for controlling their particle size to 50-100 pm. Three kinds of films with their
thickness around 30 to 120 pm have been fabricated by increasing the number ofsoaking from 1, 3 and 5. X-ray diffraction (XRD),
laser microscopy, scanning electron microscopy (SEM) revealed that the middle portion of films consisted of about 55 mass%
2r6,33Ee6.61O1.67,
34
maso/o
tetragonal ZrO2 Q-ZrO), 8 masso% monoclinic ZrO2 (m-ZrO2), and 4 masso% cr-A12O3; these crystalline
phases might be explained by the decomposition of meltrng c-ZrO2 (ss) passing through the high temperature plasma,
followed by the
rapid thermal quenching on the substrate. The volume t-ZrO2 ratios vs. m-ZrO2 in the fi1ms are 65-80oh, suggesting that high
mechanical properties could be expected. Nano-indentation analysis showed Vickers hardness
H, of 12.8 and 14.3 GPa
were
achieved for 3 and 5 soaking-pass films, respectively. And also high fracture toughness has been expected from the high areas within
the load-displacement curves that were obtained during nano-indentation. Thermal conductivity o1 of 9.4 W'm-l K-1, which is much
reduced from o, (14.0
it
W'm-l'K-'1 of SUS304, was attained for the 5-pass film. From these good mechanical and thermal properties,
has been proved that the thermal sprayed ZrO2-Al2O3
thick films formed on the metal substrates could have higher application
capability.
Key words : ZrO2-Al2O3 ceramic fl1m, thermal spray, mechanical and thermal properties
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The Microstructure and Mechanical Properties of ZrO2-AlzO: Thick Film
Formed on the SUS304 Sheet Using Thermal Spray
Ken HIRota*, Xiaoteng Gn, Masaki Kano, Muhammad RraL Hiroluki MIYAMoTo
(Received September 7 ,2016)
AZrO2-Al2O3-based thick
film
has been formed on the SUS 304 stainless-steel sheet using a thermal spray
plasma spraying: APS). The chemical composition
of
in air (atmospheric
starting raw materiai (cttbrc ZrO2 solid solution: c-ZrO2(ss)) is
which has been prepared by the neutralization co-precipitation method followed by the
T5molYoZrO2(l.5mo1%Y2O3)-25molo/oAl2O3,
calcination of 1373 K( 1 100'C) for several hours in air for controlling their particle size to 50-100 pm. Three kinds of films with their
thickness around 30 to 120 pm have been fabricated by increasing the number ofsoaking from 1, 3 and 5. X-ray diffraction (XRD),
laser microscopy, scanning electron microscopy (SEM) revealed that the middle portion of films consisted of about 55 mass%
2r6,33Ee6.61O1.67,
34
maso/o
tetragonal ZrO2 Q-ZrO), 8 masso% monoclinic ZrO2 (m-ZrO2), and 4 masso% cr-A12O3; these crystalline
phases might be explained by the decomposition of meltrng c-ZrO2 (ss) passing through the high temperature plasma,
followed by the
rapid thermal quenching on the substrate. The volume t-ZrO2 ratios vs. m-ZrO2 in the fi1ms are 65-80oh, suggesting that high
mechanical properties could be expected. Nano-indentation analysis showed Vickers hardness
H, of 12.8 and 14.3 GPa
were
achieved for 3 and 5 soaking-pass films, respectively. And also high fracture toughness has been expected from the high areas within
the load-displacement curves that were obtained during nano-indentation. Thermal conductivity o1 of 9.4 W'm-l K-1, which is much
reduced from o, (14.0
it
W'm-l'K-'1 of SUS304, was attained for the 5-pass film. From these good mechanical and thermal properties,
has been proved that the thermal sprayed ZrO2-Al2O3
thick films formed on the metal substrates could have higher application
capability.
Key words : ZrO2-Al2O3 ceramic fl1m, thermal spray, mechanical and thermal properties
+-.)- lj: ZrO2-A120: lz7 i y)
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Fig. 9. Nano-indented load-strain cur-ves of (a)
SUS304 and (b)-(d) themal sprayed ZrO2(Y2Q)
films formed on the SUS304
-25molYoAlzO3
with
?r,(r,. A H"6F.EaftH,fH
)
ffiH
tv :1 =7
1z
15.5 Gpa
7r.
*.k,
A12O3
r\
alEtlF-ffiL, = 7;lr)y l-.EHo Ce i* 0.s3 &
H-frvr:. +-,fAorij#! 14.0 w.m 1'K',tEEfi1120 pm (5 /i;z.),
E
c
s
iv) 6F,Ei* 12.8 GPa (: riz) -14.3 Gpa (5 /ix),
y) t-zro2rHE*! 6s-80%Tfr>D , ffififfiffid&Sn,fLt#tffi
E
o
:4
n\ff4+
I
,
{i;-..,
l0
50
Thickness
?0
90
1
l0
13fi
vi) flE€+tj, 14.0---+9.4 w'm-1.K 1 t.,{ET (rz 7
y 2 zflHtt f.6W#A.rrR)
151
rffilm Iurrl
Tb,>t:. 1'rklJwh{HtzT i y,
Fig. 10. Thermal conductivity of SUS304 sheets
coated with thermal sprayed ZIO2(Y2O)25molYoAl2O3 films formed on the sheet as a
#n+i+A:AILSri, h,->,
GFRP
85.
function of the thickness of films.
-
3t16,
100
-
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7.Rtr+D#ilffi,
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