Preparation and spray drying of Al2O3–TiO2 nanoparticle suspensions to obtain nanostructured coatings by APS

Al2O3–TiO2 coatings were deposited on austenitic stainless steel coupons from nanostructured powders by atmospheric plasma spraying (APS). Commercial suspensions of nanosized Al2O3 and TiO2 particles were used as starting materials. Mixtures of these suspensions and of more concentrated suspensions of Al2O3 and TiO2 were then agglomerated into plasma sprayable feedstock. Agglomeration was performed by spray drying, followed by consolidation thermal treatment. powders were successfully deposited, yielding coatings that were well bonded to the substrates. The coating microstructure thus consisted of semi-molten feedstock agglomerates surrounded by fully molten particles that acted as binders. Agglomerates from suspensions with higher solids contents yielded coatings with lower porosity and fewer semi-molten areas.