Glass-alumina composite coatings by plasma spraying. Part I: Microstructural and mechanical characterization

Composite coatings on ceramic tiles have been produced by plasma-spraying waste glass powders together with alumina as reinforcing phase. Obtaining a tough coating, in which a high amount of waste glass can be recycled, is the aim of the study. Glass powders with different particle size distributions were tested; coatings with increasing glass volume fractions (0%, 20%, 40%, 60%, 80%, 100%) were sprayed. Furthermore, two different kinds of alumina feedstocks were employed, namely, a commercial plasma-spray powder and a more economical laboratory manufactured spray-dried powder. Vickers microhardness, fracture toughness and abrasion resistance have been measured. The coatings were tested both in as-sprayed condition and after a thermal treatment. An abrasion resistance comparable to common industrial glazes has been obtained with as much as 60% of glass volume fraction, employing fine glass powders (< 45 μm). No significant decrease in mechanical properties has been noticed replacing the commercial alumina powder with the spray-dried one.