• Journal of the Korea Academia-Industrial cooperation Society
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• v.21 no.6
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• pp.204-211
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• 2020

The high-velocity oxy-fuel (HVOF) thermal spraying coating technique has been considered a promising replacement for traditional electrolytic hard chrome plating (EHC), which caused environmental pollution and lung cancer due to toxic Cr⁶⁺. In this paper, two types of cermet coatings were prepared by HVOF spraying: WC-CoCr and WC-CrC-Ni coatings. The produced coatings were analyzed extensively in terms of the micro-hardness, porosity, crystalline phase and microstructure using a hardness tester, optical microscopy, X-ray diffraction, and scanning electron microscopy (including energy dispersed spectroscopy (EDS)), respectively. The wear and friction behaviors of the coatings were evaluated comparatively by reciprocating sliding wear tests at 25 ℃, 250 ℃, and 450 ℃. The results revealed correlations among the microstructures, metallic binder matrixes, porosities, and wear performance of the coatings. For example, WC-CoCr coatings showed better sliding wear resistance than WC-CrC-Ni coatings, regardless of the test temperature due to the more homogeneous microstructure, Co-rich, Cr-rich metallic binder matrix, and lower porosity.

• Journal of the Korea Convergence Society
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• v.12 no.12
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• pp.145-151
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• 2021

This study aimed to investigate the efficient conduct of HA coating on Ti Gr4 for the practical use of medical device. Ti Gr4 alloy specimens measuring 𝜱 25mm × 1mm were sprayed with hydroxyapatite using thermal spray according to ASTM F1185-88. The surface was evaluated at #120, #400, #1,000 sandpaper and barrel finishing. Each coating properties was analyzed using SEM, UTS 20,000psi cap. and in vitro cytotoxicity. Surface morphology consists of well molten particles with very little resolidified or unmolten areas. The average Ca/P ratio is 1.74 which is in good agreement with theoretical value of 1.67. The average roughness Ra is very representative of roughness of specimen. The coatings are dense and well adhered to the substrate. The average bond strength was 61.74 MPa with a standard deviation of 4.06 which indicates fairly reliable results for ASTM 633 type tests. Variations in results from jig design, epoxy used, crosshead speeds etc. in vitro cytotoxicity result had a Grade 3. The results of the study are expected to be helpful in osseointegration and plasma-spray HA coated Ti Gr4 are more satisfactory in HA coating thickness elevation which is preferable to any other system.

• Journal of the Korea Organic Resources Recycling Association
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• v.31 no.3
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• pp.35-41
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• 2023

In this study, silicon sludge generated in semiconductor manufacturing process is recycled and applied as materials for pigments and paints. In detail, metallic impurities are removed from silicon sludge to obtain plate-like silicon sludge powder (SW-sludge), which is then coated with titanium dioxide via sol-gel method (TCS-sludge). SW-sludge and TCS-sludge are dispersed in hydrophilic transparent varnish and sprayed onto glass substrates to observe the possibility for the application as materials for pigments and paints. Notably, the applicability of TCS-sludge-based paint is improved compared to SW-sludge-based paint after the titanium dioxide coating. Moreover, the color of TCS-sludge-based paint turns into white. Accordingly, it is confirmed that the applicability and hydrophilicity are improved by the presence of outer titanium dioxide layer. In this regard, it is expected that the recycled TCS-sludge may be a future material for the application as pigments and paints.

• Journal of the Korean Ceramic Society
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• v.50 no.6
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• pp.353-358
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• 2013

The hot corrosion behavior of plasma sprayed 4 mol% $Y_2O_3-ZrO_2$ (YSZ) thermal barrier coatings (TBCs) with volcanic ash is investigated. Volcanic ash that deposited on the TBCs in gas-turbine engines can attack the surface of TBCs itself as a form of corrosive melt. YSZ coating specimens with a thickness of 430-440 ${\mu}m$ are prepared using a plasma spray method. These specimens are subjected to hot corrosion environment at $1200^{\circ}C$ with five different duration time, from 10 mins to 100 h in the presence of corrosive melt from volcanic ash. The microstructure, composition, and phase analysis are performed using Field emission scanning electron microscopy, including Energy dispersive spectroscopy and X-ray diffraction. After the heat treatment, hematite ($Fe_2O_3-TiO_2$) and monoclinic YSZ phases are found in TBCs. Furthermore the interface area between the molten volcanic ash layers and YSZ coatings becomes porous with increases in the heat treatment time as the YSZ coatings dissolved into molten volcanic ash. The maximum thickness of this a porous reaction zone is 25 ${\mu}m$ after 100 h of heat treatment.

• Journal of the Korean institute of surface engineering
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• v.52 no.6
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• pp.283-288
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• 2019

MCrAlY overaly coatings are used as oxidation barrier coatings to prevent degradation of the underlying substrate in high temperature and oxidizing environment of the hot section of gas turbines. Therefore, oxidation resistance in high temperature is important property of MCrAlY coatings. Also, coefficients of thermal expansion (CTE) of MCrAlY have middle value of that of Ni-based superalloys and oxides, which have the effect of preventing the delamination of the surface oxides. Cyclic oxidation test is one of the most useful methods for evaluating the high temperature durability of coatings used in gas turbines. In this study, NiCoCrAlY overlay coatings were formed on Inconel 792(IN 792) substrates by vacuum plasma spraying process. Vacuum plasma sprayed NiCoCrAlY coatings and IN 792 susbstrates were exposed to 1000℃ one-hour cyclic oxidation environment. NiCoCrAlY coatings showed lower weight gain in short-term oxidation. In long-term oxidation, IN 792 substrates showed higher weight loss due to delamination of surface oxide but NiCoCrAlY coatings showed lower weight loss. X-ray diffraction (XRD) analysis showed α-Al2O3 and NiCr₂O₄ was formed during the cyclic oxidation test. Through cross-section observation using scanning electron microscopy (SEM) and electron back scatter diffraction (EBSD) analysis, thermally grown oxide (TGO) layer composed of α-Al₂O₃ and NiCr₂O₄ was formed and the thickness of TGO increased during 1000℃ cyclic oxidation test. β phase in upper side of NiCoCrAlY coating was depleted due to oxidation of Al and outer beta depletion zone thickness also increased as the cyclic oxidation time increased.

• Corrosion Science and Technology
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• v.6 no.4
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• pp.147-153
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• 2007

This study sought to investigate the reaction of Co-binder containing tungsten with molten zinc. Four kinds of Co-W alloys (pure, 10%W, 20%W, 30%W) were prepared using the powder metallurgy method. The specimens were immersion-tested in molten pure zinc baths at $460^{\circ}C$. To evaluate the corrosion property in molten zinc, the weight loss of the specimen was measured after the immersion tests at different immersion times (10~300 min.). Co-10%W alloys, compared with pure cobalt, showed no effect of tungsten addition on the reaction rate in molten zinc. The relationship between the weight loss and the square root of immersion period represents a straight line in both pure cobalt and Co-10%W alloy. The Co-Zn reaction layer in Co- 1O%W alloy consists of $\gamma2$, $\gamma1$, $\gamma$ and ($\beta1$ phases. The rate of weight loss significantly increases and the weight loss behavior is not well accord with the linear relationship as the tungsten content in the Co-W alloy increases. The $\beta1$ layer was not formed on the Co-20%W alloy and neither was a stable Co-Zn intermetallic compound layer found on the Co-30%W alloy. The main cause of increase in reaction rate with increasing tungsten content is related with the instability of the Co-Zn reaction phases as seen on micro-structural analysis.

• Journal of Welding and Joining
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• v.27 no.2
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• pp.38-43
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• 2009

In this study, we investigated photocatalytic ability of plasma sprayed $TiO_2$ and Ag sputtering $TiO_2$(Ag-$TiO_2$) coatings. A sputtering processes were adopted to coat the surface of $TiO_2$ with Ag(99.99%). Ag was sputtered at 10mA, 450V for $1{\sim}11$ seconds. $TiO_2$ and Ag-$TiO_2$ coatings were heat-treated at 250, 300, 350, $400^{\circ}C$ for $0{\sim}240$seconds. Photoelectrical conductivity was measured by four-point probe, and photodegradation was calculated by UV-V is spectrometer. Microstructure observation of $TiO_2$ and Ag-$TiO_2$ coatings were investigated by SEM. Crystal structure of $TiO_2$ and Ag-$TiO_2$ coatings were investigated by XRD. Qualitative analyses of $TiO_2$ and Ag-$TiO_2$ coatings were conducted by EDX. When $TiO_2$ coatings were heat-treated at $350^{\circ}C$ for 30 sec, photoelectrical conductivity and photodegradation were best. And in XRD analysis result, (101)/(110) relative intensity ratio of $TiO_2$(rutile) was comparably changed with photoelectrical conductivity. When Ag-$TiO_2$ coatings were heat-treated at $350^{\circ}C$ for 30 [sec] after sputtering Ag for 7 sec, Photoelectrical conductivity and photodegradation are best. Surface of coatings in such condition has very small and uniform Ag particles.

• Proceedings of the Korean Institute of Surface Engineering Conference
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• 2014.11a
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• pp.300-300
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• 2014

해양환경 하에서 대형 강구조물의 경우 장기간 부식손상을 방지하기 위해 아크 용사코팅 기술이 오래전부터 유용하게 이용되어 왔다. 아크 용사코팅 기술은 타 용사코팅 기술에 비해 경제성과 생산성이 뛰어나 대형 강구조물에 적용되고 있다. 용사재료로는 Al, Zn 또는 그 합금들이 주로 사용되어 강재에 대해 희생양극 방식효과를 나타낸다. 그러나 아크용사에 의해 적층된 코팅 층은 용사공정 중 불가피하게 수많은 기공과 산화물이 포함되어 내식성 및 내구성에 악영향을 미치게 된다. 따라서 본 연구에서는 알루미늄 합금의 용사코팅 층에 대하여 다양한 후처리를 통해 내식성과 더불어 내구성을 향상시키고자 하였다. 용사코팅은 알루미늄 합금 선재(1.6 ${\varnothing}$)를 사용하여 아크용사를 실시하였다. 용사 시 용사거리는 200 mm, 공기압력은 약 $7kg/cm^2$ 정도로 유지하면서 용사코팅을 실시하여 약 $200{\mu}m$ 두께로 코팅 층을 형성시켰다. 이후 용사코팅 층의 표면에 다양한 후처리재를 적용하였으며, 내구성을 평가하기 위하여 후처리 적용 전후 시험편에 대하여 캐비테이션 실험을 실시하였다. 캐비테이션 실험은 ASTM G32-92에 의거하여 주파수 20 kHz의 초음파 진동 장치(ultrasonic vibratory device)를 사용하였다. 그리고 시험편 표면과 발진 혼에 부착된 팁(tip)과의 거리는 1 mm로 일정하게 유지시킨 뒤, 캐비테이션 발생 시간을 변수로 하여 실험을 실시하였다. 손상된 용사코팅 층의 표면은 주사전자현미경과 광학현미경으로 관찰하였으며, 시험편 손상깊이는 3D 현미경으로 비교 분석하였다. 또한 캐비테이션 실험 전후의 무게를 측정하여 무게 감소량을 상호 비교하였다. 그리고 전기화학적 실험은 천연해수 속에서 자체 제작한 홀더(holder)를 이용하여 $0.33183cm^2$의 용사코팅 층만을 노출시켜 실시하였다. 그리고 기준전극은 은/염화은 전극을, 대극은 백금전극을 사용하였다. 분극실험을 통해 후처리 적용에 따른 용사코팅 층의 부식전위 및 부식전류밀도를 비교 평가하였다. 그 결과, 용사코팅 층에 의하여 강재에 대한 희생양극 방식전위가 확보되었으며, 후처리재가 적용된 용사코팅 층에서 내식성 및 캐비테이션 저항성이 향상되었다.

• Journal of Welding and Joining
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• v.26 no.4
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• pp.50-54
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• 2008

In this research, anode for SOFC has been manufactured from two different kinds of feedstock materials through thermal spraying process and the properties of the coatings were characterized and compared. One kind of feedstock was manufactured from spray drying method which includes nano-components of NiO, YSZ (300 nm) and graphite. And the other is manufactured by blending the micron size NiO coated graphite, YSZ and graphite powders as feedstock materials. Microstructure, mechanical properties and electrical conductivity of the coatings as-sprayed, after oxidation and after hydrogen reduction containing nano composite which is prepared from spray-dried powders were evaluated and compared with the same properties of the coatings prepared from blended powder feedstock. The coatings prepared from the spray dried powders has better properties as they provide larger triple phase boundaries for hydrogen oxidation reaction and is expected to have lower polarization loss for SOFC anode applications than that of the coatings prepared from blended feedstock. A maximum electrical conductivity of 651 S/cm at $800^{\circ}C$ was achieved for the coatings from spray dried powders which much more than that of the average value.

• Korean Journal of Metals and Materials
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• v.46 no.10
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• pp.646-651
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• 2008

The electrolytic reduction of spent oxide fuel involves the liberation of oxygen in a molten LiCl electrolyte, which results in a chemically aggressive environment that is too corrosive for typical structural materials. It is essential to choose the optimum material for the process equipment handling molten salt. IN713LC is one of the candidate materials proposed for application in electrolytic reduction process. In this study, yttria-stabilized zirconia (YSZ) top coat was applied to a surface of IN713LC with an aluminized metallic bond coat by an optimized plasma spray process, and were investigated the corrosion behavior at $675^{\circ}C$ for 216 hours in the molten salt $LiCl-Li_2O$ under an oxidizing atmosphere. The as-coated and tested specimens were examined by OM, SEM/EDS and XRD, respectively. The bare superalloy reveals obvious weight loss, and the corrosion layer formed on the surface of the bare superalloy was spalled due to the rapid scale growth and thermal stress. The top coatings showed a much better hot-corrosion resistance in the presence of $LiCl-Li_2O$ molten salt when compared to those of the uncoated superalloy and the aluminized bond coatings. These coatings have been found to be beneficial for increasing to the hot-corrosion resistance of the structural materials for handling high temperature lithium molten salts.