Metallurgical and Ceramic Protective Coatings

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1 Metallurgical and Ceramic Protective Coatings

2 Metallurgical and Ceramic Protective Coatings Edited by Chemistry Division Naval Research Laboratory Washington D.C. lun! CHAPMAN & HALL London Weinheim. New York Tokyo Melbourne Madras

3 Published by Chapman & Hall, 2-6 Boundary Row, London SEt 8HN, UK Chapman & Hall, 2-6 Boundary Row, London SEI 8HN, UK Chapman & Hall GmbH, Pappelallee 3, Weinheim, Germany Chapman & Hall USA, 115 Fifth Avenue, New York NY 10003, USA Chapman & Hall Japan, ITP-Japan, Kyowa Building, 3F, Hirakawacho, Chiyoda-ku, Tokyo 102, Japan Chapman & Hall Australia, 102 Dodds Street, South Melbourne, Victoria 3205, Australia Chapman & Hall India, R. Seshadri, 32 Second Main Road, CIT East, Madras , India First edition Chapman & Hall Softcover reprint of the hardcover 1st edition 1996 Typeset in 1O/12pt Times by AFS Image Setters Ltd, Glasgow ISBN-13: DOl: / e-isbn-13: Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the UK Copyright Designs and Patents Act, 1988, this publication may not be reproduced, stored, or transmitted, in any form or by any means, without the prior permission in writing of the publishers, or in the case of reprographic reproduction only in accordance with the terms of the licences issued by the Copyright Licensing Agency in the UK, or in accordance with the terms of licences issued by the appropriate Reproduction Rights Organization outside the UK. Enquiries concerning reproduction outside the terms stated here should be sent to the publishers at the Glasgow address printed on this page. The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made. A catalogue record for this book is available from the British Library 9 Printed on permanent acid-free text paper, manufactured in accordance with ANSIjNISO Z and ANSIjNISO Z (Permanence of Paper).

4 Contents Contributors Acknowledgment 1 Introduction 1.1 Protective coatings 1.2 Stresses 1.3 Selection of coating materials 1.4 Methods of application 1.5 Electroplating - an example of a technology 1.6 Plan of this book 2 Electrodeposition of refractory metals from molten salts 2.1 Introduction 2.2 Experimental techniques 2.3 The refractory metals 3 Metalliding 3.1 Introduction 3.2 The metalliding process 3.3 Properties of metallided layers IX xiii

5 VI Contents 3.4 Individual metalliders Conclusions Electrodeposition of refractory compounds from molten salts - borides, carbides and silicides Introduction Methodology Boron and the borides Silicon and the silicides Carbon and the carbides Conclusions Laser assisted surface coatings 74 J. Mazumder 5.1 Laser surface alloying Laser surface cladding Laser chemical vapor deposition (LCVD) Sol-gel derived ceramic films - fundamentals and applications 112 C. Jeffrey Brinker, Carol S. Ashley, Richard A. Cairncross, Ken S. Chen, Alan J. Hurd, Scott T. Reed, Joshua Samuel, P. Randall Schunk, Robert W. Schwartz and Cathy S. Scotto 6.1 Introduction Sol-gel chemistry Deposition by dip-coating Deposition by spin-coating Effects of entrained condensed phases Drying of films Control of film microstructure Applications Summary 148 Acknowledgments Solid phase cladding 152 S.B. Dunkerton 7.1 Introduction Explosive cladding Roll bonding 164

6 7.4 Friction surfacing 7.5 Resistance cladding 7.6 Hot isostatic pressing 7.7 Summary Contents Vll Thermal barrier coatings R.L. Jones 8.1 Introduction 8.2 Material requirements 8.3 Stabilization of zirconia 8.4 Phase transformation reactions of stabilized zirconia 8.5 Identification of phases in stabilized zirconia 8.6 Zirconia thermal barrier coatings 8.7 Causes for failure of zirconia TBCs 8.8 Alleviation of TBC hot corrosion 8.9 Future uses and trends for zirconia TBCs Pack cementation diffusion coatings Robert Bianco and Robert A. Rapp 9.1 Principles and history 9.2 Range of applicability 9.3 Technical aspects 9.4 Possibilities for improvement 9.5 Summary Acknowledgments Thermal spray coatings H. Herman and S. Sampath 10.1 Introduction 10.2 Thermal spray processes 10.3 Feed materials 10.4 Particle-plasma interaction and process control 10.5 Deposit formation dynamics 10.6 Materials science of thermal spray deposits 10.7 Thermal spray coating applications 10.8 Thermal spray and advanced manufacturing 10.9 Summary

7 Vlll Contents 11 Degradation of coatings by high temperature atmospheric corrosion and molten salt deposits N. Birks, G.H. Meier and F.S. Pettit 11.1 Introduction 11.2 Metallic coatings 11.3 Ceramic coatings 11.4 Erosion 12 Measurement of coating adhesion David Rickerby 12.1 Introduction 12.2 Surface engineering 12.3 The requirements of an ideal adhesion test 12.4 Methods of adhesion evaluation 12.5 Summary Index

8 Contributors Carol S. Ashley Robert Bianco Department of Materials Science and Engineering Ohio State University Columbus OR N. Birks Metallurgical and Materials Engineering Department University of Pittsburgh Pittsburgh PA C. Jeffrey Brinker Center for Microengineered Ceramics University of New Mexico Albuquerque NM Richard A. Cairncross

9 x Ken S. Chen S.B. Dunkerton The Welding Institute Abington Cambridge CBl 6AL United Kingdom Contributors H. Herman Thermal Spray Laboratory Department of Materials Science and Engineering University of New York Stony Brook NY Alan J. Hurd R.L. Jones Chemistry Division Naval Research Laboratory Washington D.C J. Mazumder Center for Laser Aided Materials Processing University of Illinois Urbana IL G.H. Meier Metallurgical and Materials Engineering Department University of Pittsburgh Pittsburgh PA F.S. Pettit Metallurgical and Materials Engineering Department University of Pittsburgh Pittsburgh PA 15261

10 Contributors Robert A. Rapp Department of Materials Science and Engineering Ohio State University Columbus OH Scott T. Reed David Rickerby Rolls-Royce Surface and Technology Group Derby DE2 8BJ United Kingdom S. Sam path Thermal Spray Laboratory Department of Materials Science and Engineering University of New York Stony Brook NY Joshua Samuel P. Randall Schunk Robert W. Schwartz Cathy S. Scotto Chemistry Division Naval Research Laboratory Washington D.C Xl

11 Acknowledgment I would like to thank my wife Faith for extensive editorial assistance in the preparation of this book and for literature searches at the Library of Congress.

oviet dvanced Composites echnology eries EDITED BY A. G. Bratukhin and V. S. Bogolyubov SERIES EDITORS J. N. Fridlyander and I. H.

oviet dvanced Composites echnology eries SERIES EDITORS J. N. Fridlyander and I. H. Marshall T E C H N O L O G Y EDITED BY A. G. Bratukhin and V. S. Bogolyubov Composite Manufacturing Technology Soviet