Abstract
This paper discusses the application of ceramic thermal spray coatings on tools such as cast iron ladles, heat element protectors, and steel moulds to replace pure ceramic and ceramic slurry coated tools for extended life and lower light metal casting operation cost. Numerous ceramic coating materials were tested based on thermodynamic and mechanical properties, as well as commercial availability and cost. The work involved thermodynamic modelling, coating microstructure optimisation of ceramic/metallic and bond layers on different substrates, as well as the thermal spray processes. Two coating materials offered much better corrosion resistance to molten aluminium than the rest. The optimised coating microstructures showed much better thermal shock resistance. The ceramic thermal spray coated tools had much longer life than ceramic slurry coated tools. Issues associated with the application of ceramic thermal spray coatings were also addressed.
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