Amorphization of ZrO2 + CeO2 powders through mechanical milling for the use of kinetic spray

Songlin Li, Lei Wang, Yuming Xiong, Gyuyeol Bae, Changhee Lee

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The coating formation in a kinetic spray process mainly depends on the impact of inflight particles at a high velocity. The plastic deformation at the impact interface would disrupt the native oxide scale on the particle and the substrate to generate the intimate contact of the atomic structures. Accordingly, it poses a challenge in producing ceramic coating during kinetic spray because of the lack of plasticity of ceramic powders at room temperature. In this study, we proposed to prepare ZrO2 ceramic coatings using partially amorphized powder with nanometer size in the kinetic spray process. To prepare the powder for the use of the kinetic spray, the amorphization and grain refinement of ZrO2 powder in mechanical ball milling were studied. The results showed that the amorphization and grain refinement were improved because of the formation of solid solution when the CeO2 agent was added. Subsequently, a nearly spherical powder was achieved via spray drying using the milled powders. The plasticity of the milled powders was tested in the kinetic spray process using Nitrogen as process gas. A dense ZrO 2-CeO2 coating with a thickness of 50 μm was formed, whereas spraying milled ZrO2 powder can only lead to an inhomogeneous dispersion of the destructible particles on the surface of the substrate.

Original languageEnglish
Pages (from-to)3717-3722
Number of pages6
JournalJournal of Materials Engineering and Performance
Issue number12
Publication statusPublished - 2013 Dec 1



  • amorphization
  • ceramics
  • kinetic spray
  • mechanical milling
  • phase transformation

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