Induction plasma spheroidization of ZrB2-SiC powders for plasma-spray coating

To improve the microstructure and properties of ZrB2-SiC (ZrB2-30 vol%SiC, Z7S3) coatings, a facile synthesis route involving induction plasma spheroidization (IPS) has been proposed, and the morphologies, particle size distributions, and phase compositions of the feedstock powders were analysed by scanning electron microscopy and focused ion beam techniques. The obtained results showed that the surfaces of the produced powders contained eutectic-like and granular zones. Owing to the existence of a temperature gradient, the internal microstructure of the IPS-treated powder exhibited a three-layered structure consisting of a ′surface shell′, a ′transition layer′, and a ′porous core′. Additionally, the properties of the IPS-treated samples were compared with those of the spray-dried (SD) powders. The former exhibited good plastic deformation properties, and their single splats contained flattened structures, while the single splats of the SD powder melted only partially retaining some of their original characteristics.