Microstructural characterization of radio frequency and direct current plasma-sprayed Al2O3 coatings

Microstructures of radio frequency (RF) and direct current (DC) plasma-sprayed Al2O3 coatings deposited onto steel substrates were characterized using scanning electron microscopy (SEM), X-ray diffraction (XRD), electron microprobe analysis (EMPA), polarizing optical microscopy (OM), and transmission electron microscopy (TEM), Because RF and DC plasmas produce different particle heating and acceleration, the morphology, phase structure, and fracture modes of the coatings vary substantially, In the case of RF coatings, a clear lamellar microstructure with relatively thick lamellae was observed, which is due to the large particles and the lon particle velocities, with alpha-Al2O3 as the predominant phase and with delamination type of fracture detected on the fracture surface. In contrast! the DC coatings consisted of predominantly metastable gamma-Al2O3 as well as amorphous phases, with a mixed fracture mode of the coating observed. In spite of limited interfacial interdiffusion detected by EMPA TEM shelved an interfacial layer existing at the interface between the coating and the substrate for both cases. For RF coatings, the interfacial layer on the order of 1 mu m was composed of three sublayers, each of which was different in composition and morphology. Howe cer, the interfacial layer for the DC coating consisted primarily of an amorphous phase, containing both coating and substrate materials with or without platelike microcrystals; although in some regions a thick amorphous Al2O3 layer was in direct contact with the substrate.