Effect of TiO<sub>2</sub> Content on the Corrosion and Thermal Resistance of Plasma-Sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> Coatings
Modern industrial systems and biomass-fired furnaces require surface treatments that can withstand aggressive chemical, thermal, and corrosive environments. This study investigates the corrosion and thermal resistance of plasma-sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub&g...
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2025-05-01
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| author | Viktorija Grigaitienė Liutauras Marcinauskas Airingas Šuopys Romualdas Kėželis Egidijus Griškonis |
| author_facet | Viktorija Grigaitienė Liutauras Marcinauskas Airingas Šuopys Romualdas Kėželis Egidijus Griškonis |
| author_sort | Viktorija Grigaitienė |
| collection | DOAJ |
| description | Modern industrial systems and biomass-fired furnaces require surface treatments that can withstand aggressive chemical, thermal, and corrosive environments. This study investigates the corrosion and thermal resistance of plasma-sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> coatings produced using a DC air–hydrogen plasma spray process. Coatings of compositions of Al<sub>2</sub>O<sub>3</sub>, Al<sub>2</sub>O<sub>3</sub>-3 wt.% TiO<sub>2</sub>, Al<sub>2</sub>O<sub>3</sub>-13 wt.% TiO<sub>2</sub>, and Al<sub>2</sub>O<sub>3</sub>-40 wt.% TiO<sub>2</sub> were deposited on steel substrates with a Ni/Cr bond layer by plasma spraying. The coatings were characterized by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) to evaluate their morphology, elemental composition, and crystalline phases. Electrochemical tests were performed in a naturally aerated 0.5 mol/L NaCl solution and cyclic thermal–chemical exposure tests (500 °C using 35% KCl) to assess their corrosion kinetics and thermal stability. The results indicate that pure Al<sub>2</sub>O<sub>3</sub> and low TiO<sub>2</sub> (3 wt.%) coatings exhibit fine barrier properties, while coatings with a higher TiO<sub>2</sub> content develop additional phases (e.g., Ti<sub>3</sub>O<sub>5</sub>, Al<sub>2</sub>TiO<sub>5</sub>) that improve thermal resistance but reduce chemical durability. |
| format | Article |
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| issn | 2073-4352 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | MDPI AG |
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| series | Crystals |
| spelling | doaj-art-9203fc9c15b94a17bca6abfdc8a505642025-08-20T02:33:38ZengMDPI AGCrystals2073-43522025-05-0115543910.3390/cryst15050439Effect of TiO<sub>2</sub> Content on the Corrosion and Thermal Resistance of Plasma-Sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> CoatingsViktorija Grigaitienė0Liutauras Marcinauskas1Airingas Šuopys2Romualdas Kėželis3Egidijus Griškonis4Plasma Processing Laboratory, Lithuanian Energy Institute, Breslaujos Str. 3, LT-44403 Kaunas, LithuaniaPlasma Processing Laboratory, Lithuanian Energy Institute, Breslaujos Str. 3, LT-44403 Kaunas, LithuaniaPlasma Processing Laboratory, Lithuanian Energy Institute, Breslaujos Str. 3, LT-44403 Kaunas, LithuaniaPlasma Processing Laboratory, Lithuanian Energy Institute, Breslaujos Str. 3, LT-44403 Kaunas, LithuaniaFaculty of Chemical Technology, Kaunas University of Technology, LT-44249 Kaunas, LithuaniaModern industrial systems and biomass-fired furnaces require surface treatments that can withstand aggressive chemical, thermal, and corrosive environments. This study investigates the corrosion and thermal resistance of plasma-sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> coatings produced using a DC air–hydrogen plasma spray process. Coatings of compositions of Al<sub>2</sub>O<sub>3</sub>, Al<sub>2</sub>O<sub>3</sub>-3 wt.% TiO<sub>2</sub>, Al<sub>2</sub>O<sub>3</sub>-13 wt.% TiO<sub>2</sub>, and Al<sub>2</sub>O<sub>3</sub>-40 wt.% TiO<sub>2</sub> were deposited on steel substrates with a Ni/Cr bond layer by plasma spraying. The coatings were characterized by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) to evaluate their morphology, elemental composition, and crystalline phases. Electrochemical tests were performed in a naturally aerated 0.5 mol/L NaCl solution and cyclic thermal–chemical exposure tests (500 °C using 35% KCl) to assess their corrosion kinetics and thermal stability. The results indicate that pure Al<sub>2</sub>O<sub>3</sub> and low TiO<sub>2</sub> (3 wt.%) coatings exhibit fine barrier properties, while coatings with a higher TiO<sub>2</sub> content develop additional phases (e.g., Ti<sub>3</sub>O<sub>5</sub>, Al<sub>2</sub>TiO<sub>5</sub>) that improve thermal resistance but reduce chemical durability.https://www.mdpi.com/2073-4352/15/5/439Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> coatingsplasma sprayingDC plasma torchcoating morphologycorrosive resistance |
| spellingShingle | Viktorija Grigaitienė Liutauras Marcinauskas Airingas Šuopys Romualdas Kėželis Egidijus Griškonis Effect of TiO<sub>2</sub> Content on the Corrosion and Thermal Resistance of Plasma-Sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> Coatings Crystals Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> coatings plasma spraying DC plasma torch coating morphology corrosive resistance |
| title | Effect of TiO<sub>2</sub> Content on the Corrosion and Thermal Resistance of Plasma-Sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> Coatings |
| title_full | Effect of TiO<sub>2</sub> Content on the Corrosion and Thermal Resistance of Plasma-Sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> Coatings |
| title_fullStr | Effect of TiO<sub>2</sub> Content on the Corrosion and Thermal Resistance of Plasma-Sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> Coatings |
| title_full_unstemmed | Effect of TiO<sub>2</sub> Content on the Corrosion and Thermal Resistance of Plasma-Sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> Coatings |
| title_short | Effect of TiO<sub>2</sub> Content on the Corrosion and Thermal Resistance of Plasma-Sprayed Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> Coatings |
| title_sort | effect of tio sub 2 sub content on the corrosion and thermal resistance of plasma sprayed al sub 2 sub o sub 3 sub tio sub 2 sub coatings |
| topic | Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub> coatings plasma spraying DC plasma torch coating morphology corrosive resistance |
| url | https://www.mdpi.com/2073-4352/15/5/439 |
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