Effect of granulometric composition of raw materials on performance of ceramic coating on copper prepared by slurry method

Abstract The slurry method was used to form a ceramic coating on copper with a NiCoCrAlY transition layer. The raw materials were optimized using FactSage software, with SiO2, Al2O3, and ZrO2 being combined in proportions of 64.1%, 17.6%, and 18.3%, respectively. The sintering temperature was set to 600 °C, three granulometric compositions of ceramic aggregates were selected, and samples A, B, and C were fabricated to analyse the effects of particle size on the coating phase compositions and microstructures. However, sample C broke due to the formation of disordered-albite and thus, was not subjected to further analysis. The bonding strength, wear resistance, and thermal shock resistance of samples A and B were tested, with sample B performing better than sample A in all the above tests. This indicates that the optimization of the particle size of the ceramic aggregates plays an important role in improving the performance of a ceramic coating.