Hybrid aerosol deposition of dense Al2O3 coatings and evaluation of the through-thickness effect

Ceramic coatings improve the surface functionality and durability of structures by overcoming corrosion, heat, wear, and friction in various industries. In this context, the utilization of fine ceramic particles significantly improves the physical and mechanical properties compared to conventional large feedstock particles owing to the improved physical and mechanical properties with the reduction of grain size. However, direct spraying of the fine particles is still a big challenge with the main drawbacks of poor flowability and the difficulty of injecting.

Recently, hybrid aerosol deposition (HAD) has been proposed as a new coating method to deposit homogeneous nanostructured ceramic coatings via the utilization of mesoplasma and solid particle deposition.

This study will discuss the implementation of HAD for the deposition of dense and uniform ceramic coatings on different substrate materials, and the evaluation of the through-thickness effect. In addition, the deformation behavior during HAD will be discussed.