YSZ/Ti-6Al-4V/HA blended powder has been plasma sprayed to produce composite coatings. The YSZ and HA coated Ti-6Al-4V powders were prepared by a ceramic slurry mixing method, and used as the feedstock for the plasma spray process. The microstructures, phase composition, microhardness, Young’s modulus, and tensile adhesion strength of the composite coatings were found to respond correspondingly to variations in net plasma energy and the plasma gun-substrate standoff distance. The following findings have been made in the study:
The application of HA and YSZ coated Ti-6Al-4V composite powders has been proven to ensure satisfactory chemical homogeneity and prevent Ti alloy from oxidation during plasma spraying. There was no detection of b-TCP, TTCP except a small amount of CaO and a-TCP through XRD.
HA, YSZ and Ti-6Al-4V were distributed uniformly in the coatings. HA/YSZ/Ti-6Al-4V solid solution was formed during plasma spraying which could be helpful towards the improvement of the mechanical properties, as indicated by the microhardness measurements.
Post-spray heat treatment at 600℃and 700℃, was found as a potential approach to further improve the mechanical properties of composite coatings. However, significant amount of TiO2 was, however, formed when heat treatment was performed at 700℃.
The microhardness, Young’s modulus and bond strength were found to increase significantly with the addition of YSZ. The mechanical properties were associated with the microstructure of the coatings, such as porosity, interlamellar structure. Coatings sprayed at a net plasma energy of 12kW and a standoff distance of 8.5 cm possessed the most favorable mechanical properties.
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