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Novel Fe-Based Amorphous Composite Coating with a Unique Interfacial Layer Improving Thermal Barrier Application.

Zheng Zhou1, Feng-Xi Han1, Hai-Hua Yao2

  • 1Faculty of Materials and Manufacturing, Beijing University of Technology, Beijing 100124, China.

ACS Applied Materials & Interfaces
|May 4, 2021
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A novel Fe-based amorphous composite coating with ceramic oxides was developed for vehicle engines. This innovative thermal barrier coating significantly enhances power efficiency by reducing thermal conductivity.

Keywords:
Fe-based amorphous alloycomposite coatingfracture toughnessinterfacial layerthermal conductivity

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Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Thermal Engineering

Background:

  • Advanced vehicle engines require improved thermal barrier coatings to enhance efficiency and durability.
  • Existing thermal barrier coatings face challenges in high-temperature performance and material compatibility.

Purpose of the Study:

  • To design and prepare a novel Fe-based amorphous composite coating with ceramic oxides for improved thermal barrier applications in vehicle engines.
  • To investigate the microstructure, properties, and thermal barrier performance of the developed composite coating.

Main Methods:

  • Atmospheric plasma spraying (APS) was used to prepare the Fe-based amorphous composite coating.
  • Microstructural analysis was performed to characterize the coating's composition and structure, including the interfacial layer.
  • Thermal conductivity and fracture toughness were measured to evaluate the coating's performance.

Main Results:

  • The composite coating featured an FeCrNbBSi amorphous metallic matrix with dispersed yttria-stabilized zirconia (YSZ) splats.
  • A unique, amorphous Si-oxide interfacial layer formed between the metallic matrix and ceramic phase.
  • The coating exhibited extremely low thermal conductivity (2.28–3.36 W/mK) and increased piston crown temperature by 18.93 °C, enhancing power efficiency.
  • Fracture toughness remained comparable to monolithic amorphous coatings, attributed to the Si-oxide layer.

Conclusions:

  • The developed Fe-based amorphous composite coating demonstrates significant potential as an innovative metal-based thermal barrier coating for vehicle engines.
  • The Si-oxide interfacial layer is crucial for improved thermal barrier ability by increasing interfacial thermal resistance.
  • Interfacial engineering of coatings offers promising avenues for future development in thermal management applications.