Search Results (52)

This study aims to assess the thermal dynamics of supporting structures during laser-assisted debonding of bonded yttrium-stabilized zirconia (YSZ) ceramic. We tested the hypothesis that the heat transfer to dentin analog material and composite resin resembles that of dentin. Thirty sintered YSZ (ZirCAD, Ivoclar, Schann, Liechtenstein) slabs (4 mm diameter, 1 mm thickness) were air particle abraded, followed by two coats of Monobond Plus (Ivoclar). The slabs were bonded to exposed occlusal dentin, NEMA G10 dentin analog, or composite resin cylinders using Multilink Automix (Ivoclar) dual-cured cement. The bonded YSZ specimens (n = 10/group) subjected to irradiation with an Er,Cr:YSGG laser (Waterlase MD, Biolase, Foothill Ranch, CA, USA) at 7.5 W, 25 Hz, with 50% water and air for 15 s. Heat transfer during laser irradiation was monitored with an infrared camera (Optris PI 640, Optris GmbH, Berlin, Germany) at 0.1-s intervals. Data were analyzed using one-way ANOVA, which showed no significant differences in mean temperature between zirconia and cement layers across the substrates (composite resin, G10, dentin) (p = 0.0794). These results suggest flexibility in substrate choice for future thermal dynamics studies under laser irradiation. Full article

Yttria-Stabilized Zirconia (YSZ) is an important material in thermal barrier coatings (TBCs), which are widely applied in aviation engines and ground gas turbines. Therefore, the quality inspection of the YSZ layer is of great significance for the safety of engines and gas turbines. In this work, the YSZ powder is mixed with Polytetrafluoroethylene (also known as teflon) in different mass ratios and pressed into tablets with different thicknesses. A terahertz time-domain spectroscopy system is used to obtain their time-domain spectra, and their frequency spectra are then obtained by fast Fourier transform. Based on theory formulas, we obtained the frequency-dependent curves of the absorption coefficient, refractive index, and absorbance of the YSZ tablets. The results show that the YSZ tablets have characteristic absorption peaks in the terahertz band, and these peaks are affected by the mass ratio of YSZ to teflon and the thickness of the tablets. Finally, we conducted a terahertz Raman spectroscopy test of the YSZ tablets for the first time. The results show that in the range from 0 to 1600 cm⁻¹, there are about ten strong Raman peaks. More importantly, these peaks are approximately independent of the mass ratio and the thickness of tablets. This study is of great significance for the nondestructive testing of TBC quality using terahertz spectroscopy technology. Full article

The high yttria content of a stabilized zirconia (YSZ) (38 wt% Y₂O₃) coating was deposited by atmospheric plasma spraying (APS) from Metco 207 powders on an Inconel 718 (Ni-based superalloy) substrate. As a metal coating connection, a layer of cermet powder (Ni-20% Al—410NS) was used before the ceramic layer deposition. The electro-chemical corrosion resistance of these materials was tested using Inconel cylinders with a diameter of 10 mm and a thickness of 1 mm, with and without the ceramic layer. Linear and cyclic measurements were obtained in H₂SO₄ electrolyte media at pH = 2. Electro-impedance spectroscopy (EIS) experiments were performed on the sample covered with the ceramic layer to evaluate the interface behavior. Scanning electron microscopy (SEM), along with equipment to determine chemical composition, and an energy dispersive spectrometry (EDS) detector were used to characterize the material surface before and after corrosion tests. It was observed that the corrosion resistance of Inconel was influenced by the bonding layer and the ceramic coating. Full article

Oral implantology faces a multitude of technical challenges in light of current clinical experience, underlining the need for innovation in implantable medical devices in both mechanical and biological terms. Objectives: This study explores the influence of the thickness factor of calcium-doped zirconia (Ca-SZ) coatings deposited by PVD on their intrinsic mechanical properties and the determinism of the latter on adhesion to the TA6V alloy substrate after mechanical loading for applications in dental implantology. Methods: Three separate thicknesses of 250 nm, 450 nm and 850 nm were evaluated in terms of mechanical strength, modulus of elasticity and adhesion to the substrate, in accordance with ISO 20502:2005. Results: The results show an increase in apparent modulus of elasticity with thickness, reaching values of around 25.05 GPa and 36.3 GPa, close to the cortical bone for the 250 nm and 450 nm thick coatings, respectively. Adhesion tests show a progressive improvement up to 450 nm, followed by a similar observation at 850 nm, underlining the importance of optimal thickness to balance mechanical protection and biomechanical compatibility. Furthermore, the initial roughness and topography of the substrate were not influenced by the different thicknesses of the Ca-SZ coating. Conclusions: Together, these results reinforce the potential of Ca-SZ coatings to minimise stress shielding in dental implants. Full article

The micro-arc oxidation (MAO) technique was used to grow in situ oxidation coating on the surface of R60705 zirconium alloy in Na₂SiO₃, Na₂EDTA, and NaOH electrolytes. The thickness, surface morphology, cross-section morphology, wear resistance, composition, and structure of the micro-arc oxidation coating were analyzed by an eddy current thickness measuring instrument, XPS, XRD, scanning electron microscopy, energy spectrometer, and wear testing machine. The corrosion resistance of the coating was characterized by a polarization curve and electrochemical impedance spectroscopy (EIS). The results show that, with the increase in frequency, the single-pulse discharge energy decreases continuously, and the coating thickness shows a decreasing trend, from the highest value of 152 μm at 400 Hz to the lowest value of 87.5 μm at 1000 Hz. The discharge pore size on the surface of the coating gradually decreases, and the wear resistance and corrosion resistance of the coating first increase and then decrease. The corrosion resistance is the best when the frequency is 400 Hz. At this time, the corrosion potential is −0.215 V, and the corrosion current density is 2.546 × 10⁻⁸ A·cm⁻². The micro-arc oxidation coating of zirconium alloy is mainly composed of monoclinic zirconia (m-ZrO₂) and tetragonal zirconia (t-ZrO₂), in which the content of monoclinic zirconia is significantly more than that of tetragonal zirconia. Full article

The presented manuscript demonstrates the effect of the thickness of a zinc alloy sublayer on the corrosion resistance and stability of three types of bi-layer systems composed of Co- or Ni-modified zinc coatings (both as sublayers) and a top sol–gel ZrO₂ film in a 5% NaCl solution. In order to obtain more detailed information, the alloy sublayers were electrodeposited with three different thicknesses (1, 5 and 10 µm, respectively) on a low-carbon steel substrate. Three consecutive dip-coated ZrO₂ sol–gel layers were deposited thereafter on the individual zinc alloy sublayers. For comparison, an ordinary electrodeposited zinc coating was obtained and investigated. The aim of this study was to evaluate the effect of the thickness of the zinc-based sublayer on the protective characteristics of the bi-layer systems. The surface morphology features and the phase composition of the latter systems were examined using scanning electron microscopy (SEM), atomic force microscopy (AFM), water contact angle (WCA) measurements and X-ray diffraction (XRD) analyses. The corrosion stability was evaluated by means of potentiodynamic polarization (PDP) curves and polarization resistance (Rp) measurements. The zirconia finish layers possessed an amorphous, dense and hydrophobic nature, while the sublayers were multicrystalline. The results confirmed the increased corrosion resistance of the protective system, which contains electrodeposited sublayer of Zn-Co alloy with a 10 µm thickness in a corrosive test medium. Full article

Hard alloy end mills are commonly employed for milling zirconia prostheses in dentistry. Nano-diamond-coated milling bits ensure high processing efficiency, accuracy, extended tool life, and reduced processing costs. This study aims at comparing various effects of cutting dental zirconia with nano-diamond-coated and ordinary milling bits. Two types of milling bits, one with nano-diamond coating and one without, were used to cut the dental zirconia green blanks (Ø98.5 mm, thickness: 25 mm) at three different speeds (1000, 1500, and 2000 rpm) in a dental milling machine. The unsintered and sintered zirconia surfaces were evaluated with glossmeter, optical profilometer for surface roughness, SEM, and EDX. The glossiness of the sintered zirconia block was statistically higher than that of the unsintered block (p < 0.05). For sintered zirconia, the nano-diamond-coated milling bit yielded a statistically (p < 0.05) higher glossiness in all spindle speeds than uncoated, save for the uncoated milling bit used at 1500 rpm. However, in terms of roughness, only sintering showed to be a statistically significant factor (p < 0.001) outweighing other two factors, and sintered zirconia always yielded lower surface roughness than the unsintered counterpart. Overall, the nano-diamond-coated milling bit can be operated at various speeds, resulting in a higher gloss on the sintered zirconia block, while an ordinary, uncoated milling bit can only achieve the same glossiness at a designated speed. The type of milling bits and the speeds have no significant effect on the surface roughness. Full article

Antibacterial coatings are becoming increasingly attractive for application in the field of biomaterials. In this framework, we developed polymer coating zirconia with antibacterial activity using the “grafting from” methodology. First, 1-(4-vinylbenzyl)-3-butylimidazolium chloride monomer was synthesized. Then, the surface modification of zirconia substrates was performed with this monomer via surface-initiated photo atom transfer radical polymerization for antibacterial activity. X-ray photoelectron spectroscopy, ellipsometry, static contact angle measurements, and an atomic force microscope were used to characterize the films for each step of the surface modification. The results revealed that cationic polymers could be successfully deposited on the zirconia surfaces, and the thickness of the grafted layer steadily increased with polymerization time. Finally, the antibacterial adhesion test was used to evaluate the antibacterial activity of the modified zirconia substrates, and we successfully showed the antibacterial activity against Staphylococcus aureus and Pseudomonas aeruginosa strains. Full article

The failure of premature thermal cycling spalling off is the bottleneck problem currently faced by yttrium oxide partially stabilized zirconia (YSZ) ceramic-based sealing coatings. Studies on the thermal cycling performance of coatings with “brick-mud” structures were carried out by experimental and simulation methods in this paper. The results showed that, as the thickness of “mud” layer increased, the bonding strength of the “brick-mud” structure coatings gradually decreased. When the thickness of the “mud” layer was about 3 μm and 10 μm, the thermal cycling lives of the T1 and T2 coatings were improved by 90.0% and 135.7%, respectively, compared with conventional coating (T0 coating), while that of the T3 coating (containing thick “mud” layers of about 20 μm) was decreased by 81.4%. The stress field of M2 “mud” layers with different thicknesses was subjected to a comprehensive effect by thermal mismatch stress and pores in “brick” layer. Compared with the medium and thick “mud” layers, the thin “mud” layer sustained obvious larger ${\sigma }_{22 max}$ and ${\sigma }_{12 max}$, indicating its potential for the preferential initiation of transverse microcracks. In addition, the thin “mud” layer withstood the largest ${\sigma }_{11 max}$ and had the strongest potential for longitudinal crack growth. Both transverse and longitudinal cracking could consume energy during thermal cycling and reduce the stress concentration at the top coating/bond coating interface. These were the main reasons for the improvements in the thermal cycling performances of the T1 and T2 coatings. The degree of crack deflection and the capacity of energy dissipation in the “mud” layer increased significantly with its thickness. However, the propagation length of transverse cracks also gradually increased in the meantime. Especially when the “mud” layer was 20 μm, the length of the transverse cracks increased rapidly. Thus, early interlayer delamination failure occurred in the T3 coating during thermal cycling. Full article

In this work, we have developed and characterized a ceramic composite based on a core of directionally solidified calcium zirconate-calcium stabilized zirconia (CZO-CSZ) eutectic composite coated with a bioactive glass-ceramic. The aim is to research new orthopedic implants as an alternative to conventional 3Y-TZP bioinert ceramics. The CZO-CSZ eutectic rods were grown from the melt of rods of CaO-ZrO₂ in the eutectic composition using the laser floating zone technique (LFZ). The mechanical results indicated that directional eutectics prepared with this technique exhibited good mechanical strength and significant hardness and toughness. The LFZ technique was also used to melt the bioactive coating previously placed by dip coating on the CZO-CSZ rod surface. Depending on the thickness of the coating and the applied laser power, an alloying or coating process was achieved. In the first case, the coating was diluted with the surface of the eutectic cylinder, leading to the segregation of the calcium zirconate and zirconia phases and the formation of a bioactive phase embedding zirconia particles. In the second case, a layer of ceramic glass was formed, well attached to the eutectic cylinder. These layers were both studied from the microstructural and bioactivity points of view. Full article

The laser sintering process and modification of yttria-stabilized zirconia (YSZ) coatings subjected to electrophoretic deposition (EPD) on YSZ air-plasma-sprayed (APS) thermal barrier coatings (TBCs) were investigated. A Ni-based superalloy was plasma-sprayed using yttria-stabilized zirconia (YSZ) to create a thermal barrier coating with a 400 μm thickness. The electrophoretic deposition (EPD) technique was used to deposit the nanopowder of YSZ on the surface of YSZ TBCs. In this study, a technology based on the direct sintering of a green EPD layer using a laser beam was employed. The best conditions for the deposition overlay of the YSZ coating using a DC current were obtained with an applied voltage of 40 V, deposition time of 5 min, and suspension concentration of 10 g/L. Iodine was added to the solutions as a stabilizing agent. To overcome the problems of high sintering temperatures, laser sintering was adopted as a new approach. The microstructures of all the specimens were studied using field emission scanning electron microscopy (FESEM) with energy-dispersive X-ray spectroscopy (EDS) analysis. Surface roughness was investigated using atomic force microscopy (AFM) analysis and the central line average (CLA). The direct laser sintering (DLS) process for the EPD overlay on the surface of the TBCs caused a reduction in surface roughness and porosity, and improvements in the microstructural and mechanical properties of the surface coatings were observed. Full article

This study focused on the numerical simulation of the distribution of residual stress in yttria-stabilized zirconia (YSZ) coatings prepared with atmospheric plasma spraying (APS). We particularly investigated the stress distribution around the interface between the top coat and bond coat. During thermal spray deposition, droplets and particles deposit on the substrate in a complex manner, causing interface waviness and non-uniform stress distribution. Therefore, residual stress is an important consideration when preparing thermal barrier coatings (TBCs). Residual stresses directly affect the performance of bond coats (BCs) and ceramic top coats (TCs). To accurately evaluate residual stress, we considered interface waviness and the thickness of the ceramic top coat and conducted a detailed analysis of stress distribution. The results show that compressive stress exists at the TC/BC interface, which may be caused by the mismatch in the thermal expansion coefficient between the YSZ top coat and the substrate, potentially leading to coating delamination. Moreover, the residual stress at the TC/BC interface significantly increases with an increasing YSZ thickness. When the top-coat thickness exceeds 300 μm, stress concentration and failure of the coating are likely to occur. Meanwhile, the optimized thermal spray experiment results confirm that the residual stress at the BC/YSZ interface of the thermal barrier coating is tensile stress, with a maximum value of 155 MPa, which is consistent with the finite element calculation results. Furthermore, the failure modes of TBCs with rough interface conditions are discussed in detail. Our research provides important guidance for TBC design and optimizing their performance. Full article

Zirconia ceramics (ZrO₂) have been used for a variety of applications due to their superior physical properties, including in machining tools and dentures. Nonetheless, due to its extreme hardness and brittleness in both sintered and half-sintered forms, zirconia is difficult to machine. In this study, half-sintered zirconia blocks are milled with tungsten carbide milling tools which arecoated with diamond film using hot filament chemical vapor deposition (HFCVD) at various substrate-to-filament distances. The objective was to determine the effect of substrate-to-filament distances on the coating thickness, diamond purity, coating grain size, and ZrO₂ machining performance during HFCVD. The experimental results show that, in HFCVD, the grain size and coating thickness of the diamond film on milling tools tend to decrease when the substrate-to-filament distances decrease. Tool failure happened at a cutting time of 200 min for all coated tools. However, the machining quality in terms of surface topology, surface roughness, and tool condition is superior for diamond-coated milling tools with smaller grain sizes and thinner thicknesses. It can be concluded that diamond milling tools with a smaller grain size and lesser thickness produced under shorter substrate-to-filament distances have a superior machining performance and a longer tool life. This study could potentially be used for parameter optimization in the production of coated tools. Full article

This paper focused on studying the performance of a nanostructured thermal barrier coating (TBC) system deposited by APS, which had a bond coat with inter-lamellar porosities that resulted during the manufacturing process. The higher porosity level of the bond coat was studied as a possible way to keep the thickness of the TGO under control, as it is distributed on a higher surface, thereby reducing the chance of top-coat (TC) spallation during long-term oxidation and high-temperature thermal shock. The TBC system consisted of nanostructured yttria partially stabilized zirconia (YSZ) as a top coat and a conventional NiCrAlY bond coat. Inter-lamellar porosities ensured the development of a TGO distributed on a higher surface without affecting the overall coating performance. Based on long-term isothermal oxidation tests performed at 1150 °C, the inter-lamellar pores do not affect the high resistance of nanostructured TBCs in case of long-term iso-thermal oxidation at 1150 °C. The ceramic layer withstands the high-temperature exposure for 800 h of maintaining without showing major exfoliation. Fine cracks were discovered in the ceramic coating after 400 h of isothermal oxidation, and larger cracks were found after 800 h of exposure. An increase in both ceramic and bond-coat compaction was observed after prolonged high-temperature exposure, and this was sustained by the higher adhesion strength. Moreover, in extreme conditions, under high-temperature thermal shock cycles, the TBC withstands for 1242 cycles at 1200 °C and 555 cycles at 1250 °C. Full article

In this study, white thermal control coatings were produced on a 6061 Al alloy using plasma electrolytic oxidation (PEO). The coatings were mainly formed by incorporating K₂ZrF₆. The phase composition, microstructure, thickness, and roughness of the coatings were characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), a surface roughness tester, and an eddy current thickness meter, respectively. The solar absorbance and infrared emissivity of the PEO coatings were measured using a UV–Vis–NIR spectrophotometer and FTIR spectrometer, respectively. The addition of K₂ZrF₆ to the trisodium phosphate electrolyte was found to significantly enhance the thickness of the white PEO coating on the Al alloy, with the coating thickness increasing in proportion to the concentration of K₂ZrF₆. Meanwhile, the surface roughness was observed to stabilize at a certain level as the K₂ZrF₆ concentration increased. At the same time, the addition of K₂ZrF₆ altered the growth mechanism of the coating. In the absence of K₂ZrF₆ in the electrolyte, the PEO coating on the Al alloy surface predominantly developed outwards. However, with the introduction of K₂ZrF₆, the coating’s growth mode transitioned to a combination of outward and inward growth, with the proportion of inward growth progressively increasing in proportion to the concentration of K₂ZrF₆. The addition of K₂ZrF₆ substantially enhanced the adhesion of the coating to the substrate and endowed it with exceptional thermal shock resistance, as the inward growth of the coating was facilitated by the presence of K₂ZrF₆. In addition, the phase composition of the aluminum alloy PEO coating in the electrolyte containing K₂ZrF₆ was dominated by tetragonal zirconia (t-ZrO₂) and monoclinic zirconia (m-ZrO₂). With the increase in K₂ZrF₆ concentration, the L* value of the coating increased from 71.69 to 90.53. Moreover, the coating absorbance α decreased, while the emissivity ε increased. Notably, at a K₂ZrF₆ concentration of 15 g/L, the coating exhibited the lowest absorbance (0.16) and the highest emissivity (0.72), which are attributed to the enhanced roughness resulting from the substantial increase in coating thickness caused by the addition of K₂ZrF₆, as well as the presence of ZrO₂ with higher emissivity within the coating. Full article