Tribological behaviour of alumina-titania nanostructured coatings produced by air plasma spray technique

Nanostructured Al2O3-TiO2 wear resistant coatings were produced by air plasma spray from plasma-densified agglomerated nano-powders. Conventional Al2O3-TiO2 coatings were also deposited for direct comparison of tribological performance. Operating parameters were optimized by a DOE (Design of Experiment) procedure, to produce coherent and well adherent ceramic coatings and to minimize dwell times in the torch in order to reduce the risk of excessive grain growth or complete remelting. Optimal tribological behaviour was selected as the main goal function. Microstructural characterization of APS nanostructured coatings confirmed the presence of fully molten areas combined with unmolten particles still retaining their spherical morphology, and with elongated particles whose microstructure showed initial stages of grain growth and recrystallization processes. Coatings produced with the final set of deposition parameters were tested for micro-hardness, elastic modulus and unlubricated wear resistance against alumina. Results clearly indicate that nanostructured coatings produced from plasma densified nanostructured precursors exhibit considerably improved performances, evaluated in terms of worn out volume and mass loss.