Prime surface coating: a novel method for making thick ceramic coatings

Kashefi, M., 2005. Prime surface coating: a novel method for making thick ceramic coatings. PhD, Nottingham Trent University.

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The use of coatings to protect or enhance the performance of a component manufactured from a different material is well recognised as a cost effective solution in many engineering situations. This approach is particularly appropriate for ceramic materials deposited as coatings. However, in general such coatings are either relatively thin (<0.1mm) with very good properties, or thicker but with mechanical properties that are somewhat less good.

The present study has investigated the development of a novel coating technique, primarily concentrating on ceramics in the first instance, with the aim of producing relatively thick uniform coatings with good mechanical properties. This novel method is based on initially depositing a coating mixture based on a fine ceramic powder in a cyanoacrylate binder. This experimental investigation has concentrated on the selection and examination of several possible materials for the coatings and substrates and has developed procedures for the mixing, application, debinding and sintering of the coating mixtures.

It was determined that ceramic powders could be well dispersed in an alkoxyethyl cyanoacrylate binder to a maximum volume fraction of 0.45 for uni-modal powders with mean particle sizes ~8 μm, and 0.58 for a bi-modal alumina powder, Para-toluene sulphonic acid and caffeine have been identified as suitable polymerization inhibitors and initiators respectively. Coatings with controlled thicknesses between 0.4 and 1.0 mm have been successfully deposited onto metallic and ceramic substrates. SEM micrographs show good uniformity of the coating and that successful adhesion can be achieved, as also shown by the joint shear strength test results. The versatile properties of the cyanoacrylates suggest that there are potential applications for the coatings at the cured stage.

This study also describes and discusses the debinding and sintering of alumina and zirconia coatings. Using 96% alumina substrates resulted in successful sintering of the debonded layers to full density. The microstructural studies show good uniformity in the coatings with good adhesion to the substrate. The indentation hardness and toughness values measured in the sintered coatings were comparable with the results obtained on the commercial alumina used as the substrate.

Item Type: Thesis
Creators: Kashefi, M.
Date: 2005
ISBN: 9781369316513
Divisions: Schools > School of Science and Technology
Record created by: Linda Sullivan
Date Added: 30 Sep 2020 09:50
Last Modified: 08 Sep 2023 13:57

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