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Plasma-sprayed 2:1-mullite coatings deposited on aluminium substrates

¹ Oceangate Consulting, Questenbergweg 48, 34346 Hann.Münden, Germany
² Department of Mineralogy, Universität Heidelberg, 69120 Heidelberg, Germany
³ GeoForschungsZentrum Potsdam, 14478 Potsdam, Germany

^* Corresponding author, e-mail: robert.heimann{at}ocean-gate.de

2:1-mullite coatings of (17–23) ± 6 µm thickness were deposited by atmospheric plasma spraying (APS) onto flat aluminium coupons. Scanning transmission electron microscopy (STEM) showed that the coatings immediately adjacent to the substrate interface consisted predominately of an aluminium silicate glass with varying Al/Si ratios. Residual compressive coating stresses with in-plane levels ranging from 100 to 300 MPa were determined by Cr³⁺ photoluminescence piezospectroscopy. The aluminium silicate glass was characterised by wide-angle x-ray scattering (WAXS) using synchrotron radiation to determine the composition (62–63 mole% Al₂O₃) as well as the amount of glass in the coatings (32 ± 2%).

Key-words: mullite, plasma-sprayed coatings, residual stress, aluminium silicate glass, photoluminescence piezospectroscopy, wide-angle x-ray scattering.