• Corrosion Science and Technology
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• v.19 no.2
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• pp.100-107
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• 2020

The demand for powder-coated steel used in the marine industry is increasing owing to their superior corrosion resistance. However, the powder coatings used in commercial products can deteriorate easily by the penetration of brine. In an attempt to suppress brine penetration into the powder coating and significantly increase the corrosion resistance, three types of oxide particles were added to the coating. Electrochemical impedance spectroscopy tests in 3.5% NaCl solution were performed to evaluate the corrosion behaviors of the powder coating with oxide particles. The results showed that the addition of SiO₂ particles to a powder coating severely decreased the corrosion resistance due to the easy detachment of agglomerated SiO₂ particles with a coarse size from the coating layer. In contrast, the TiO₂ and SnO₂-added coatings showed better corrosion resistance, and the TiO₂-added coating performed best in the test conducted at room temperature. However, conflicting results were obtained from tests conducted at a higher temperature, which may be attributed to the effective suppression of brine penetration by the fine SnO₂ particles uniformly distributed in the coating.

• Journal of Welding and Joining
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• v.15 no.1
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• pp.116-124
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• 1997

A scope of this study is to establish the optimum plasma spray conditions for fine ($5\mu\textrm{m}$) $Al_2O_3$ powder. However, the flowability of the $Al_2O_3$ powder is not so good because of irregular particle shape and fine particle size. Therefore, powder feeding system was modified by 1) change of powder feeding line material from polymer to copper 2) shorten the powder feeding tube length 3) heating the powder feeding system to $80^{\circ}C$4) vibrating the powder feeding line continuously, in order to feed the fine powder homogeneously. The homogeneous powder feeding conditions were obtained with the modified powder feeding system by controlling the powder carrier gas flow and the powder flow rate indicator. The best plasma spraying conditions for the fine $Al_2O_3$ powder were found out as 40kw gun power, 80 g/min. powder feed rate and 50 mm working distance after characterizing the microstructure, hardness and wear loss of the $Al_2O_3$ coating layer.

• Journal of Welding and Joining
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• v.14 no.6
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• pp.101-108
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• 1996

In this study, WC-l7wt% Co composite powder for thermal spray was fabricated by spray drying method. The agglomerated composite powder had spheroidal morphology and the particle size distribution was 20~60${\mu}{\textrm}{m}$. WC and Co were distributed homogeneously. However, the strength of the spray-dried agglomerate was low due to the pores within the agglomerate. Therefore, the spray-dried agglomerate was broken down during HVOF thermal spray and the microstructure was inhomogeneous with many pores within the coating layer. And the decomposition of WC to W and $W_{6}$ $C_{2.54}$ was accelerated. The strength and flowability of the agglomerate were greatly improved by sintering heat treatment(110$0^{\circ}C$, 1 hour, hi atmosphere), and then the coating layer showed dense and homogeneous microstructure with well-developed splats. The hardness of the coating layer was H $v_{300}$ = 1072.2.2.

• Journal of Powder Materials
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• v.21 no.3
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• pp.229-234
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• 2014

This study manufactured a CIG-based composite coating layer utilizing a new warm spray process, and a mixed powder of Cu-20at.%Ga and Cu-20at.%In. In order to obtain the mixed powder with desired composition, the Cu-20at.%Ga and Cu-20at.%In powders were mixed with a 7:1 ratio. The mixed powder had an average particle size of $35.4{\mu}m$. Through the utilization of a warm spray process, a CIG-based composite coating layer of $180{\mu}m$ thickness could be manufactured on a pure Al matrix. To analyze the microstructure and phase, the warm sprayed coating layer underwent XRD, SEM/EDS and EMPA analyses. In addition, to improve the physical properties of the coating layer, an annealing heat treatment was conducted at temperatures of $200^{\circ}C$, $400^{\circ}C$ and $600^{\circ}C$ for 1 hour each. The microstructure analysis identified ${\alpha}$-Cu, $Cu_4In$ and $Cu_3Ga$ phases in the early mixed powder, while $Cu_4In$ disappeared, and additional $Cu_9In_4$ and $Cu_9Ga_4$ phases were identified in the warm sprayed coating layer. Porosity after annealing heat treatment reduced from 0.75% (warm sprayed coating layer) to 0.6% (after $600^{\circ}C/1hr$. heat treatment), and hardness reduced from 288 Hv to 190 Hv. No significant phase changes were found after annealing heat treatment.

• Journal of the Korean Ceramic Society
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• v.32 no.8
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• pp.909-914
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• 1995

From alumina powder and TEOS, $\alpha$-Al2O3/SiO2 composite powder for reaction-sintered mullite was synthesized by heterogeneous coagulation and surface coating, and investigated the mullitization reaction and sintering behavor of these powders. In $\alpha$-Al2O3/SiO2 composite powder prepared by heterogeneous coagulation, each alumina particles were surrounded by silica particles of 50~60 nm in size. And the alumina particles in composite powder prepared by surface coating were coated by uniform silica layer with thickness of 50 nm. In both methods, mullitization reaction was completed at 1$650^{\circ}C$ for 3h, and specimen sintered above 145$0^{\circ}C$ was about 95% fo the theoretical relative density. Mullite grains formed from the reaction with composite powders showed spherical shape with a size of 1~2${\mu}{\textrm}{m}$.

• Proceedings of the Korean Institute of Electrical and Electronic Material Engineers Conference
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• 2007.11a
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• pp.339-339
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• 2007

Metal coating on ceramic powder has long been attracting interest for various applications such as superconductor where the brittle nature of high temperature ceramic superconductor was complemented by silver coating and metalloceramics where mechanical property improvement was achieved via electroless plating. More recently it has become of great interest in embedded passive device applications since metal coating on ceramic particles may result in the enhancement of the dielectric properties of ceramic-polymer composite capacitors. In our study, nickel ion-containing solution was used for coating commercial capacitor-grade $BaTiO_3$ powder. After filtering process, the powder was dried and heat-treated in 5% forming gas at $900^{\circ}C$. XRD and TEM were utilized for the observation of crystallization behavior and morphology of the particles. It was found that the nickel coating characteristics were strongly dependent on the several parameters and processing variables, such as starting $BaTiO_3$ particle size, nickel source, solution chemistry, coating temperature and time. In this paper, the effects of these variables on the coating characteristics will be presented in some detail.

• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09a
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• pp.509-510
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• 2006

Correlations between in-flight particle, splat and coating microstructure of thermally sprayed Ni20Cr were investigated. Flame spray and arc spray systems were employed for spraying Ni20Cr powder and Ni20Cr wire, respectively. The results showed that the arc spray process produced a broader size distribution for both in-flight particles and splats compared to flame process. Flower-like splat morphology was obtained from the arc spray whereas a pancake-like splat was obtained by flame spray. Ni20Cr coating sprayed by arc process had a denser microstructure, lower porosity and better adhesion at the interface.

• Journal of Powder Materials
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• v.24 no.5
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• pp.370-376
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• 2017

In this study we manufacture a Ni-Cr-B-Si +WC/12Co composite coating layer on a Cu base material using a laser cladding (LC) process, and investigate the microstructural and mechanical properties of the LC coating and Ni electroplating layers (reference material). The initial powder used for the LC coating layer is a powder feedstock with an average particle size of $125{\mu}m$. To identify the microstructural and mechanical properties, OM, SEM, XRD, room and high temperature hardness, and wear tests are implemented. Microstructural observation of the initial powder and LC coating layer confirm the layer is composed mainly of ${\gamma}-Ni$ phases and WC and $Cr_{23}C_6$ carbides. The measured hardness of the LC coating and Ni electroplating layers are 653 and 154 Hv, respectively. The hardness measurement from room up to high temperatures of $700^{\circ}C$ result in a hardness decrease as the temperature increases, but the hardness of the LC coating layer is higher for all temperature conditions. Room temperature wear results show that the wear loss of the LC coating layer is 1/12 of the wear level of the Ni electroplating layer. The measured bond strength is also greater in the LC coating than the Ni electroplating.

• Journal of the Korean Institute of Electrical and Electronic Material Engineers
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• v.26 no.1
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• pp.6-12
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• 2013

Aerosol deposition(AD) coating that enable fabricate films at low temperature have begun to be widely researched for the integration of ceramics as well to realize high-speed deposition rates. For application of ceramic thick film by AD to display and electronic ceramic industry, fabrication of dense structure with a no cracking is required. In this study, to fabricate dense ceramic thick film, the effect of crystal phase of starting powder was investigated. For this study, amorphous and crystalline $SiO_2$ powders were used as starting powders. Two types of $SiO_2$ powders were deposited on glass substrate by AD. In the case of amorphous $SiO_2$ powder, the deposited films had extremely incompact and opaque layer, irrespective of particle size. In contrast to amorphous powder, in the case of crystalline powder, porous structure layer and dense microstructure with no cracking layer were fabricated depending on the particle size. The optimized starting powder size for dense coating layer was $1{\sim}2{\mu}m$. The transmittance of film reached a maximum of 76% at 800 nm.

• Proceedings of the Korean Ceranic Society Conference
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• 2003.10a
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• pp.38.2-38
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• 2003