Effect of Heat Treatment on the Microstructure and Microhardness of Nanostructural Al2O3 Coatings

Nanostructural Al2O3 coatings were formed on a steel substrate surface using a multichamber detonation sprayer. The Al2O3 coatings were characterized by a dense microstructure with porosity below 1% and hardness of 1300 ± 25 HV0.3. The transition layer between the coating and substrate was up to 15 μm thick, containing Fe-Al-type intermetallic compounds (FeAl3, Fe2Al5). Postdeposition heat treatment of the samples at 850 °C for 3 h was carried out in air and argon environments. The effect of heat treatment on the microstructure and microhardness of the Al2O3 coatings was investigated by optical microscopy, scanning and transmission electron microscopy, scanning probe microscopy, x-ray phase analysis, and Vickers hardness testing. A positive impact of postcoating heat treatment on the coating microstructure and microhardness was observed. Heat treatment resulted in an increase in the coating hardness from 1300, to 1350 ± 25 HV0.3 and 1600 ± 25 HV0.3 after annealing in air and argon, respectively. Heat treatment in argon led to a more significant increase in the α-Al2O3 phase from 47 to 81%.