Composite ceramic-metal coatings by means of combined electrophoretic deposition and galvanic methods

• Published in: Journal of materials science 2004-02, Vol.39 (3), p.839-844
• Main Authors: KRÜGER, H. G, KNOTE, A, SCHINDLER, U, KERN, H, BOCCACCINI, A. R
• Format: Article
• Language: English
• Subjects: Adhesive strength; Applied sciences; Bonding strength; Building materials. Ceramics. Glasses; Ceramic coatings; Ceramic industries; Ceramics; Cermets; Cermets, ceramic and refractory composites; Chemical industry and chemicals; Chemistry; Corrosion protection; Cross-disciplinary physics: materials science; rheology; Diffusion coating; Electrochemistry; Electrodeposition; Electrokinetics; Electrophoretic deposition; Electrophoretic plates; Ethanol; Exact sciences and technology; General and physical chemistry; Heat treatment; Interlayers; Materials science; Metal coatings; Metals. Metallurgy; Microstructure; Miscellaneous; Nanoparticles; Nickel; Other materials; Physics; Porosity; Sintering (powder metallurgy); Specific materials; Stainless steel; Stainless steels; Steel plates; Study of interfaces; Substrates; Surface treatments; Technical ceramics; Zirconium dioxide
• ISSN: 0022-2461; 1573-4803
• DOI: 10.1023/b:jmsc.0000012912.96350.d2

A method based on the combination of electrophoretic and galvanic deposition techniques has been developed to fabricate metal-ceramic composite coatings on metallic substrates. A ZrO2-Ni composite coating with interpenetrating microstructure was produced on stainless steel plates. For electrophoretic deposition of the ceramic component, a non-aqueous suspension consisting of zirconia nanoparticles, ethanol and addition of 4-hydroxybenzoic acid was optimised by electrokinetic sonic amplitude (ESA) measurements. The zirconia deposits were partially sintered to create an open porous structure (porosity = 40–50%), which was subsequently filled with Ni by galvanic deposition. The bonding strength between the composite coating and the stainless steel substrate was improved by a final heat-treatement at 950°C for 3 h which promoted the diffusion of Ni into the steel substrate and the formation of a diffusion interlayer. The high adhesion strength of the composite coating to the stainless steel substrate after the diffusion bonding heat-treatment was confirmed by 3-point flexural strength tests. The coating exhibited a homogeneous interpenetrating microstructure with hardness values >6 GPa.