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Interpenetrating phase ceramic/polymer composite coatings: Fabrication and characterization.

机译：互穿相陶瓷/聚合物复合涂层：制备和表征。

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The goals of this thesis research were to fabricate interpenetrating phase composite (IPC) ceramic/polymer coatings and to investigate the effect of the interconnected microstructure on the physical and wear properties of the coatings. IPC coatings with an interpenetrating phase microstructure were successfully fabricated by first forming a porous ceramic with an interconnected microstructure using a chemical bonding route (mainly reacting {dollar}alpha{dollar}-alumina (0.3 {dollar}mu{dollar}m) with orthophosphoric acid to form a phosphate bond). Porosity within these ceramic coatings was easily controlled between 20 and 50 vol. % by phosphoric acid addition, and was measured by a new porosity measurement technique (thermogravimetric volatilization of liquids, or TVL) which was developed. The resulting ceramic preforms were infiltrated with a UV and thermally curable cycloaliphatic epoxide resin and cured. This fabrication route resulted in composite coatings with thicknesses ranging from {dollar}sim{dollar}1{dollar}mu{dollar}m to 100 {dollar}mu{dollar}m with complete filling of open pore space.; The physical properties of the composite coatings, including microhardness, flexural modulus and wear resistance, were evaluated as a function of processing variables, including orthophosphoric acid content and ceramic phase firing temperature, which affected the microstructure and interparticulate bonding between particles in the coatings. For example, microhardness increased from {dollar}sim{dollar}30 on the Vicker's scale to well over 200 as interparticulate bonding was increased in the ceramic phase. Additionally, Taber wear resistance in the best TPC coatings was found to approach that of fully-densified alumina under certain conditions.; Several factors were found to influence the wear mechanism in the IPC coating materials. Forming strong connections between ceramic particles led to up to an order of magnitude increase in the wear resistance. Additionally, coating microhardness and ceramic/polymer interfacial strength were studied and found to be important in determining the wear mechanism and wear resistance of IPC composite coatings. A qualitative theory for wear mechanisms in these coatings was developed.; Finally, a series of transparent coatings were developed via a similar processing route, using smaller ({dollar}sim{dollar}90 nm) boehmite particles instead of 0.3 {dollar}mu{dollar}m {dollar}alpha{dollar}-alumina. Physical property control was found to mimic that found in opaque coatings, and showed increasing surface adsorption characteristics with increasing phosphoric acid content.
机译：本文研究的目的是制造互穿相复合（IPC）陶瓷/聚合物涂层，并研究相互连接的微观结构对涂层物理和磨损性能的影响。具有互穿相微结构的IPC涂层是通过首先使用化学键合途径（主要是使{alpha}α{dollar}-氧化铝（0.3 {dollar} mu {dollar} m）与正磷反应）形成具有相互连接的微观结构的多孔陶瓷而成功制造的酸形成磷酸键）。这些陶瓷涂层中的孔隙率很容易控制在20至50 vol。 ％通过添加磷酸，并通过开发的新的孔隙率测量技术（液体的热重挥发，或TVL）进行测量。用紫外线和可热固化的脂环族环氧树脂渗透所得的陶瓷预成型件并固化。这种制造途径导致复合涂层的厚度范围从{1} 11到100 to，并完全填充了开孔空间。评估了复合涂层的物理性能，包括显微硬度，挠曲模量和耐磨性，这些是加工变量的函数，包括正磷酸含量和陶瓷相烧成温度，这些变量会影响涂层的微观结构和颗粒之间的键合。例如，随着陶瓷相中颗粒间结合的增加，显微硬度从维氏标度的30美元增加到200倍以上。另外，在某些条件下，最好的TPC涂层的泰伯耐磨性接近完全致密的氧化铝。发现几个因素会影响IPC涂层材料的磨损机理。在陶瓷颗粒之间形成牢固的连接会导致耐磨性提高一个数量级。此外，对涂层的显微硬度和陶瓷/聚合物界面强度进行了研究，发现它们对确定IPC复合涂层的磨损机理和耐磨性很重要。建立了这些涂层中磨损机理的定性理论。最后，通过类似的加工路线开发了一系列透明涂层，使用的是较小的（{sim} {dollar} 90 nm）勃姆石颗粒，而不是0.3 {dollar} mu {dollar} m {dollar} alpha {dollar}-氧化铝。发现物理性能控制模仿不透明涂层中的物理性能控制，并显示出随着磷酸含量增加而增加的表面吸附特性。

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