Advances in Plasma Coatings

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Plasma Coatings, Surfaces & Interfaces".

Deadline for manuscript submissions: closed (30 September 2022) | Viewed by 5198

Special Issue Editor


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Guest Editor
Department of High-efficiency Processing Technology, Moscow State University of Technology, Vadkovsky per. 3A, 127055 Moscow, Russia
Interests: plasma; broad beams; accelerated electrons and ions; fast atoms; chemical heat treatment; combined surface hardening and coating; thin films; surface etching; cutting edge sharpening by fast atoms

Special Issue Information

Dear Colleagues,

The plasma-based surface modification technologies developed in recent years allow us to improve operational characteristics of various parts made of any materials, being it metals, dielectrics or composites. The high efficiency of this approach may be explained by the fact that under the diversified operating conditions of the parts, in all cases, the most loaded is the surface layer. Different technological techniques, such as surface layer hardening and alloying (chemical-heat treatment, implantation), coating deposition (physical and chemical methods), a combination of both methods, and other solutions use low-pressure gas discharges for the plasma generation. These are the glow discharge, vacuum arc, radio frequency (RF) and microwave discharges, as well as discharges with thermionic cathodes.

The efficiency of both the surface layer hardening and coating deposition can be appreciably improved with the use of broad beams of accelerated ions or fast neutral atoms. The ions are extracted from the gas discharge plasma by accelerating electrodes, for example, grids. The fast atoms appear due to charge exchange collisions of accelerated ions with gas molecules or due to collisions with a metal surface at a grazing incidence and recombination with electrons pulled out from the metal surface. It should be additionally emphasized that the beam-assisted deposition of coatings can be carried out using a beam of fast gas atoms obtained in the same plasma of the discharge generating metal vapor for the coating deposition; for instance, magnetron discharge or vacuum arc.

The aim of this Special Issue is to provide a review of the current state of the research and developments in the field of plasma coatings and surface modification technologies that can ensure a substantial increase in the useful life and reliability of the parts and other important manufacturing factors.

Some of the topics of particular interest to the Special Issue are as follows:

  • Filling voluminous vacuum chambers with a homogeneous plasma at the gas pressure not exceeding 0.01 Pa for the plasma immersion ion implantation into the surface of conductive parts;
  • Broad beam sources of high-energy neutral atoms for the modification of the dielectric part surface;
  • Nitriding of the parts in plasma produced by a broad ion beam injected into a vacuum chamber;
  • High-rate deposition of dielectric coatings using magnetron-sputtering systems with liquid targets;
  • High-rate low-temperature deposition of thick aluminum oxide and aluminum nitride coatings by anodic evaporation of aluminum in the arc discharge;
  • Development of pulsed detonation technology for modification of material properties and high-rate coating deposition using plasma jets;
  • Coating deposition using the cathodic arc evaporation at a number and sizes of emitted from the cathode spots droplets reduced due to supply of the reactive gas into the vacuum chamber through the cathode;
  • Influence of the plasma coatings on the stress–strain state and wear of the parts subjected to various heat and force loads;
  • Original technological equipment and setups for plasma coatings and surface hardening of the parts, including low-temperature techniques.

Prof. Dr. Alexander S. Metel
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Coatings is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • plasma immersion processing
  • neutral beams in plasma
  • surface hardening
  • high-rate coating

Published Papers (3 papers)

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Research

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12 pages, 5047 KiB  
Article
ZrSi2-SiC/SiC Gradient Coating of Micro-Structure and Anti-Oxidation Property on C/C Composites Prepared by SAPS
by Fei Liu, Hejun Li, Qiangang Fu, Xinhai He and Wei Zhang
Coatings 2022, 12(10), 1377; https://doi.org/10.3390/coatings12101377 - 21 Sep 2022
Cited by 2 | Viewed by 1749
Abstract
A ZrSi2-SiC/SiC gradient coating system was designed to reduce the thermal stress of anti-oxidation coatings for C/C composites and prolong their anti-oxidation time at a high temperature. The SiC transition layer was prepared by pack cementation and the gradient ZrSi2 [...] Read more.
A ZrSi2-SiC/SiC gradient coating system was designed to reduce the thermal stress of anti-oxidation coatings for C/C composites and prolong their anti-oxidation time at a high temperature. The SiC transition layer was prepared by pack cementation and the gradient ZrSi2-SiC outer coatings with different ZrSi2 contents added were deposited by supersonic air plasma spraying (SAPS). The micro-morphologies and phase compositions of the coatings were studied by SEM, EDS, XRD, and TG/DSC, and their anti-oxidation performances were tested by a static oxidation experiment. The findings suggested that the gradient coating with 30 wt.% ZrSi2 content displayed the optimum and dense microstructure without obvious pores and microcracks, compared with the other three proportional coatings. During the oxidation test, because of the oxidation reaction of ZrSi2 and SiC phases, a large amount of silica was formed in the coating to fill the pores and microcracks and densify the coating further. Oxidation products ZrO2 and ZrSiO4, having a high melting point and outstanding anti-oxidation property, were embedded in the SiO2 glass layer to reduce the layer volatilization rate and improve the ability to block oxygen. Therefore, the specimen with 30 wt.% ZrSi2 still kept mass gain after 188 h oxidation time at 1500 °C. However, when the oxidation time was increased to 198 h, it had a mass loss of 0.1%, because the coating compactness was destroyed by the escape of the oxidation gases. Full article
(This article belongs to the Special Issue Advances in Plasma Coatings)
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20 pages, 7331 KiB  
Article
Plasma-Beam Processing of Tools Made of SiAlON Dielectric Ceramics to Increase Wear Resistance When Cutting Nickel–Chromium Alloys
by Alexander Metel, Marina Volosova, Enver Mustafaev, Yury Melnik, Anton Seleznev and Sergey Grigoriev
Coatings 2022, 12(4), 469; https://doi.org/10.3390/coatings12040469 - 30 Mar 2022
Cited by 4 | Viewed by 2222
Abstract
This research aimed at an increase in wear resistance of round cutting plates manufactured with SiAlON dielectric ceramics through deposition of wear-resistant coatings. To increase effectiveness of the coatings, their adhesion was improved by the removal of defective surface layers from the cutting [...] Read more.
This research aimed at an increase in wear resistance of round cutting plates manufactured with SiAlON dielectric ceramics through deposition of wear-resistant coatings. To increase effectiveness of the coatings, their adhesion was improved by the removal of defective surface layers from the cutting plates before the deposition. As the depth of caverns and grooves appearing on the cutting plates due to manufacturing by diamond grinding reached 5 µm, a concentrated beam of fast argon atoms was used for the removal of defective layers with a thickness exceeding the depth of caverns and grooves. At the equal angles of incidence to the front and back surfaces of the cutting wedge amounting to 45 degrees, two-hour-long etching of rotating cutting plates provided removal of defective layers with thickness of ~10 µm from the surfaces. After the removal, the cutting edge radius of the plates diminished from 20 to 10 µm, which indicates the cutting plates’ sharpening. Wear-resistant TiAlN coatings deposited after the etching significantly improve the processing stability and increase wear resistance of the cutting plates by not less than 1.7 times. Full article
(This article belongs to the Special Issue Advances in Plasma Coatings)
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9 pages, 3410 KiB  
Brief Report
Synthesis of Gd2Zr2O7 Coatings Using the Novel Reactive PS-PVD Process
by Pawel Pędrak, Kamil Dychtoń, Marcin Drajewicz and Marek Góral
Coatings 2021, 11(10), 1208; https://doi.org/10.3390/coatings11101208 - 1 Oct 2021
Cited by 11 | Viewed by 2246
Abstract
Ceramic topcoats of thermal barrier coatings (TBCs) make it possible to increase the working temperature of the hot sections of jet engines. Yttria-stabilized zirconia oxide (YSZ) is usually used to protect the turbine blades and vanes against high temperature and oxidation. It is [...] Read more.
Ceramic topcoats of thermal barrier coatings (TBCs) make it possible to increase the working temperature of the hot sections of jet engines. Yttria-stabilized zirconia oxide (YSZ) is usually used to protect the turbine blades and vanes against high temperature and oxidation. It is necessary to develop new materials which can operate at higher temperatures in a highly oxidizing gas atmosphere. Re2Zr2O7-type pyrochlores are promising YSZ replacements. Usually, they are produced by mixing pure oxides in the calcination process at higher temperatures. In a recent article, the new concept of pyrochlore synthesis during the deposition process was presented. The new technology, called reactive plasma spray physical vapor deposition (reactive PS-PVD), was developed and a Gd2Zr2O7 (GZO) coating was achieved. The reactive PS-PVD process allowed for the use of a mixture of untreated ZrO2 and Gd2O3 powders as reactants, instead of the commercially available gadolinium zirconate powders used in other types of processes. The results of microstructure observations revealed a columnar microstructure in the produced ceramic layer. The phase composition indicated the presence of gadolinium zirconate. Thermal analysis showed a decrease in the thermal conductivity in the range of 700 to 1200 °C of the produced layers, as compared to the layer made of the currently used conventional YSZ. Full article
(This article belongs to the Special Issue Advances in Plasma Coatings)
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