Hi I would like to know what are the simplest methods to apply a thin layer of ceramic (let say calcium aluminate) on a metallic substrate. Thank you in advance!
It is strongly dependent on the basic material and composition and the necessary properties of the ceramic layer. Generally it can be said, that thin (up to approx. 10 micrometers) ceramic layers are produced by using of PVD. The layers thicker than 10 micrometers are applied by using of plasma spraying. For aluminum and titanium alloys, there are also Al2O3 and TiO2 layers which are produced by anodizing.
The simplest coating variant for aluminum is anodizing. You can produce very thin (
Well, unfortunately I need to coat specifically calcium aluminate...
In this case, only plasma spraying can help. However, I do not know anyone who coat with calcium aluminate.
The thickness of the layer is a function of the coating time while using PVD or any other method.
Not quite. For PVD and thermal spraying techniques, there are natural limits in thickness, otherwise the layer spalled off. These limits is depend on material, spray parameters and other things, but it exist. In principle, the PVD layers are not thicker than 10-20 μm and the plasma sprayed ceramic coatings are not thicker than 1-2 mm. Exceptions are the highly porous layers with cracking networks, which can also be slightly thicker. Thus, EB-PVD layers of YSZ (yttria stabilized zirconia) can be made up to about 300 μm in thickness.
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