Plasma-electrolytic oxidation of thermally sprayed aluminium coatings for high-temperature wear applications under particle-loaded hot-gas jets

陶瓷涂层，特别是氧化铝涂层，用于增加抗磨损和腐蚀的能力，以及金属表面的隔热。等离子电解氧化（PEO）热喷涂铝涂层是一种创新的生产方法，通过这种方法，即使是钢和聚合物基材也可以涂上高度耐磨的PEO涂层。未完全转化为Al2O3的Al涂层受到操作温度的强烈限制。相对脆的陶瓷涂层在大冲击角下对颗粒射流侵蚀的抵抗能力很低。该研究项目旨在使热喷涂和等离子电解处理铝涂层进入冶炼工业和动力总成生产等新应用领域。通过在铝层和PEO涂层中加入铜或镍等延展性元素，从而显著降低PEO涂层的脆性，从而在高冲击角度下显著提高抗颗粒射流侵蚀的能力。陶瓷复合涂层的较高工作温度是通过应用耐热材料如钛来实现的。

Ceramic coatings, especially of aluminium oxide, are applied to increase resistance against wear and corrosion and for thermal insulation of metallic surfaces. Plasma-electrolytic oxidation (PEO) of thermally sprayed aluminium coatings is an innovative production method by which even steel and polymeric substrates can be coated with highly abrasive wear-resistant PEO coatings. Al coatings incompletely converted to Al2O3 are strongly limited with regard to the operation temperature. The relatively brittle ceramic coatings only show a very low resistance against particle jet erosion at high impact angles. This research project aims to make thermally sprayed and plasma-electrolytically treated aluminium coatings accessible to new fields of application such as smelting industry and powertrain production. A significant decrease in brittleness of the PEO coatings by incorporating ductile elements like copper or nickel into the aluminium layer and thus into the PEO coating will be focussed on in order to achieve considerably increased resistance against particle jet erosion at high impact angles. Higher operation temperatures of the ceramic composite coatings are intended by applying heat-resistant materials like titanium.