Alumina-base plasma-sprayed materials part I: Phase stability of alumina and alumina-chromia

Aluminum oxide is a relatively cheap, abundant material that is widely used for plasma- spray applications. This material, however, exists in many crystallographic modifications with different properties. In addition, most of these modifications are metastable and cannot be used in applications employed at elevated temperatures. Usually γ, δ, or other phases form after spraying, while α phase (corundum) is often the most desirable phase due to high corrosion resistance and hardness. This paper first reviews the method of α stabilization in the as- sprayed materials offered in literature. Then, as an example, it summarizes the results of an extensive study of chromia additions to alumina. Chromia was chosen because of its complete solid solubility in alumina and its crystal lattice type, which is similar to that of alumina. It was demonstrated that the addition of approximately 20 wt% chromia results in the formation of one solid solution of (Al- Cr)2O3 in the α- modification.