Microstructure and Improved Thermal Shock Behaviour of an In Situ Formed Metal-Enamel Interlocking Coating

doi:10.1007/s40195-021-01204-6

Abstract

Abstract:

A novel metal-enamel interlocking coating was designed and prepared in situ by co-deposition of Ni-enamel composite layer and subsequent air spray of enamel with 10 wt% nanoscale Ni. During the firing process, the external enamel layer was melted and jointed with the enamel particles at the upper part of the Ni-plating layer to form the enamel pegs. Thermal shock tests of pure enamel, enamel with 10 wt% Ni composite and metal-enamel interlocking coatings were conducted at 600 °C in water and static air. The results indicated that the metal-enamel interlocking showed superior thermal shock resistance to both pure enamel and enamel with 10 wt% Ni composite coatings. The enhanced performance was mainly attributed to the advantageous effects of mechanical interlocking of the enamel pegs formed at the enamel/Ni-plating interface. Meanwhile, during thermal shock test, big clusters formed by nanoscale Ni agglomerations were oxidised to be a Ni/NiO core-shell structure while small single nanoscale Ni grains were oxidised completely, which both improved the thermal shock resistance of enamel coating significantly.

Key words: Enamel, Interlocking, Thermal shock, Nanoscale Ni

Hang Wang, Chuan Zhang, Chengyang Jiang, Lijuan Zhu, Lihong Han, Minghui Chen, Shujiang Geng, Fuhui Wang. Microstructure and Improved Thermal Shock Behaviour of an In Situ Formed Metal-Enamel Interlocking Coating[J]. Acta Metallurgica Sinica (English Letters), 2021, 34(8): 1131-1141.

Figures/Tables 13

Table 1 Nominal composition of enamel (wt%)

SiO₂	B₂O₃	Al₂O₃	Na₂O	K₂O	CoO	CaF₂
54.62	12.32	5.96	12.32	5.96	2.46	6.36

Table 2 Parameters for Ni pre-deposition by electroplating technique

Parameters	Value
NiSO₄·6H₂O	150-200 g L^-1
H₂BO₃	20-30 g L^-1
Na₂SO₄	50-80 g L^-1
NaCl	8-10 g L^-1
C₁₂H₂₅NaSO₄	0.1 g L^-1
pH value	5
Temperature	55 °C
Current density	0.5-1 A dm^-2

Fig. 1 Cross-sectional morphologies of Ni-plating layer after annealing (a), as-deposited NE10N coating (b)

Fig. 2 EPMA mapping of the two interfaces of as-deposited NE10N coating

Fig. 3 Initial cross-sectional morphologies of PE (a), E10N (b) coating samples

Fig. 4 Mass change curves of PE, E10N and NE10N coating samples after thermal shock in water at 600 °C for different times

Fig. 5 Surface and cross-sectional morphologies of PE (a, b), E10N (c, d), NE10N (e, f) after thermal shock in water at 600 °C for 60 times

Fig. 6 Mass change curves of PE, E10N, NE10N coating samples after thermal shock in static air at 600 °C for different times

Fig. 7 Cross-sectional and enlarged morphologies of PE, E10N, NE10N coating samples after thermal shock in static air at 600 °C for 200 times (a and b for PE, c and d for E10N, e and f for NE10N)

Table 3 EDS results in Fig. 7f (at.%)

	O	Na	Mg	Si	Ca	Fe	Co	Ni
Zone 1	5.06	/	/	0.66	0.64	0.69	/	92.96
Zone 2	49.77	2.28	7.32	3.27	1.73	1.70	2.35	31.57

Fig. 8 BF-STEM cross-sectional morphology of the enamel layer in NE10N coating after thermal shock at 600 °C for 200 times (a), corresponding EDS mapping (b), SAED patterns of precipitate 1 and 2 (c), corresponding line scan profile (d)

Fig. 9 Schematic illustration of NE10N coating formation

Fig. 10 Schematic illustration of stress state within E10N (a), NE10N (b) coatings during thermal shock tests

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