Effect of granulometric composition of raw materials on performance of ceramic coating on copper prepared by slurry method

The slurry method was used to form a ceramic coating on copper with a NiCoCrAlY transition layer. The raw materials were optimized using FactSage software, with SiO2, Al2O3, and ZrO2 being combined in proportions of 64.1%, 17.6%, and 18.3%, respectively. The sintering temperature was set to 600 °C, three granulometric compositions of ceramic aggregates were selected, and samples A, B, and C were fabricated to analyse the effects of particle size on the coating phase compositions and microstructures. However, sample C broke due to the formation of disordered-albite and thus, was not subjected to further analysis. The bonding strength, wear resistance, and thermal shock resistance of samples A and B were tested, with sample B performing better than sample A in all the above tests. This indicates that the optimization of the particle size of the ceramic aggregates plays an important role in improving the performance of a ceramic coating. •Ceramic coating on copper prepared by low-temperature solid-phase sintering•FactSage used to optimize formula to obtain desired phases of coating•Appropriate aggregate granularity contributes to coating phase composition.•Formation of pores related to granulometric composition of aggregates•Ceramic coating prepared by selected aggregate granularity has good properties.