Abstract
This paper introduces a new way to inject nanoparticles into a plasma flame and demonstrates its use in the deposition of dense ceramic coatings. Instead of suspensions or pastes, nanoparticles are dispersed in micro resin fragments. In this case, zirconia particles with an average diameter of 200 nm were mixed with a thermosetting acrylic liquid resin and the mixture was solidified, crushed, and screened. Micro resin fragments are fed into the plasma flame using a conventional powder feeder. The resin content mostly burns away in the plasma jet, which heats and propels the nanoparticles into the substrate. SEM analysis of the zirconia deposits shows that they are free of microcracks and pores, although carbon contamination was detected by thermogravimetry. Coating hardness tests were also conducted and the results are presented.
