Effect of TiO<sub>2</sub> Content on the Corrosion and Thermal Resistance of Plasma-Sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> Coatings

Effect of TiO<sub>2</sub> Content on the Corrosion and Thermal Resistance of Plasma-Sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> Coatings

Modern industrial systems and biomass-fired furnaces require surface treatments that can withstand aggressive chemical, thermal, and corrosive environments. This study investigates the corrosion and thermal resistance of plasma-sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub&g...

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Bibliographic Details
Main Authors: Viktorija Grigaitienė, Liutauras Marcinauskas, Airingas Šuopys, Romualdas Kėželis, Egidijus Griškonis
Format: Article
Language:English
Published: MDPI AG 2025-05-01
Series:Crystals
Subjects:
Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> coatings
plasma spraying
DC plasma torch
coating morphology
corrosive resistance
Online Access:https://www.mdpi.com/2073-4352/15/5/439
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Summary:Modern industrial systems and biomass-fired furnaces require surface treatments that can withstand aggressive chemical, thermal, and corrosive environments. This study investigates the corrosion and thermal resistance of plasma-sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> coatings produced using a DC air–hydrogen plasma spray process. Coatings of compositions of Al<sub>2</sub>O<sub>3</sub>, Al<sub>2</sub>O<sub>3</sub>-3 wt.% TiO<sub>2</sub>, Al<sub>2</sub>O<sub>3</sub>-13 wt.% TiO<sub>2</sub>, and Al<sub>2</sub>O<sub>3</sub>-40 wt.% TiO<sub>2</sub> were deposited on steel substrates with a Ni/Cr bond layer by plasma spraying. The coatings were characterized by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) to evaluate their morphology, elemental composition, and crystalline phases. Electrochemical tests were performed in a naturally aerated 0.5 mol/L NaCl solution and cyclic thermal–chemical exposure tests (500 °C using 35% KCl) to assess their corrosion kinetics and thermal stability. The results indicate that pure Al<sub>2</sub>O<sub>3</sub> and low TiO<sub>2</sub> (3 wt.%) coatings exhibit fine barrier properties, while coatings with a higher TiO<sub>2</sub> content develop additional phases (e.g., Ti<sub>3</sub>O<sub>5</sub>, Al<sub>2</sub>TiO<sub>5</sub>) that improve thermal resistance but reduce chemical durability.
ISSN:2073-4352

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