Formation of ceramic thin films using electrospray in cone-jet mode

The electrospray technique has been developed to generate fine droplets of SiC and ZrO₂ ceramic suspensions and to deposit these ceramic thin films and their bilayer on alloy substrates. SEM examinations of the microstructures of these thin films show that the films are very homogenous with a uniform particle size less than 10 μm. The deposition of a very thin bilayer with an abrupt interface indicates that the electrospray process can be well controlled. The theoretical prediction of droplet size and electric current is in good agreement with experimental results, indicating that fine suspension droplets can be generated in the cone-jet mode. Therefore it can be concluded that electrospray is a promising technique for the preparation and controllable distribution of uniform ceramic thin films and coatings with the added advantage of low cost. It could find a wide range of industrial applications in the future.