Parametric study of Al and Al2O3 ceramic coatings deposited by air plasma spray onto polymer substrate

Aluminum and ceramic (Al2O3) coatings were deposited onto the polymer substrate by air plasma spray (APS) to improve the mechanical properties of the polymer surface. The effect of spray parameters (current and spray distance in this paper) on the phase composition, microstructure and mechanical properties was investigated. Shear adhesion strength between the coatings and the substrates was also examined. The results indicate that the deposition parameters have a significant effect on the phase composition, microstructure and mechanical properties of as-spayed coatings. The maximum shear adhesion strength of the bond coats was 5.21 MPa with the current of 180 A and 190 mm spray distance.

► Al and Al2O3 ceramic were deposited onto the polymer substrate by plasma spray technology. ► Spray parameters have no effect on the phase composition of the coatings. ► The highest shear adhesion strength of the bond coating was 5.21 MPa sprayed with the current of 180 A and 190 mm. ► Very thin Al2O3 top coatings have the composition of α-Al2O3, γ-Al2O3 and aluminum was sprayed onto the polymer substrate.