BACKGROUND AND KEY FEATURES OF THERMAL SPRAY NANOSTRUCTURED CERAMIC COATINGS

Thermal spray nanostructured coatings were first developed under an ONR program supervised by Drs. Lawrence T. Kabacoff and A.K. Vasudevan entitled, “Thermal Spray Processing of Nanostructured Coatings” [1].  Since the inception of this program in 1997, nanostructured coatings derived from the ONR initiative have been successfully implemented into numerous Navy applications.  Of the different types of nanostructured coating materials studied and applied within the program, the nanostructured alumina-titania coating developed by Gell et al. [2-4] at UCONN stands out.  They developed a means of processing nanoparticles of ceramic powder into thermal sprayable feedstock.  This nanostructured coating showed enhancements in wear-resistance (2 to 4X); bond strength (up to 2X); and toughness, compared to its conventional coating counterpart.  In 2000, with the permission from ONR, FW Gartner teamed up with Mogas Industries and Perpetual Technologies to use the knowledge gained from the ONR program to develop a new nanostructured coating customized for a severe-service industrial application.  The nanostructured titania coating was developed, tested, patented, and applied onto thousands of ball valve components used in hydrometallurgical extraction of nickel and cobalt [5-8].  This coating, as seen in the nanostructured alumina-titania coating, showed improved wear-resistance, bond strength and toughness, compared to conventional titania coating.  

 

George E. Kim, Ph.D.

F.W. Gartner

Perpetual Technologies, Inc.

email: gkim@perpetualtech.ca

1. Lawrence T. Kabacoff, “Nanoceramic Coatings Exhibit Much Higher Toughness and Wear Resistance than Conventional Coatings”, The AMPTIAC Newsletter, Spring 2002, Volume 6, Number 1.
2. M. Gell with E.H. Jordan et al., “Fabrication and Evaluation of Plasma Sprayed Nanostructured Alumina-Titania Coatings with Superior Properties,” Mater. Sci. Eng., A301, pp. 80-89, 2001.
3. M. Gell with L. Shaw et al., “Development and Implementation of Plasma Sprayed Nanostructured Ceramic Coatings, Surface and Coatings Technology,” vol. 146-147, pp. 48-54, 2001.
4. D. Goberman, Y. Sohn, L. Shaw, E. Jordan, M. Gell, “Microstructure Development of Al2O3-13wt.%TiO2 Plasma Sprayed Coatings Derived from Nanocrystalline Powders,” Acta Materialia, 50, 1141-1152, 2002.
5. G.E. Kim, “Thermal Sprayed Nanostructured Coatings: Applications and Developments”, Chapter 3 of Nanostructured materials: processing, properties, and applications, edited by C.C. Koch, 2007.
6. G.E. Kim, “Nanostructured Coatings Application in High Pressure Acid Leaching Process”, Invited Speaker at the Surface Technology (SURFTEC) Group Meeting at the National Research Council of Canada, Montreal, Quebec, Canada, 2002. 
7. J. Williams, G.E. Kim, and J. Walker, “Ball Valves with Nanostructured Titanium Oxide Coatings for High-Pressure Acid-Leach Service: Development to Application”, Proceedings of Pressure Hydrometallury 2004, Banff, Alberta, Canada, October 23-27, 2004.
8. G.E. Kim, J. Williams, and J. Walker, “Nanostructured Titania Coated Titanium”, United States Patent No. 6,835,449, December 28, 2004.

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