Various alumina-based materials are applied to achieve different electrical insulation properties based on the variation of the material specific relative permittivity. Thermally sprayed mullite (Al2O3 · SiO2) can form an amorphous phase due to the high cooling rates of the process. The formation of amorphous phases causes a change in the capacitive behaviour of the coatings. The tendency to form amorphous areas can be influenced by the composition of the feedstock material or coating parameters. On the one hand, mullite coatings based on two different Al2O3 to SiO2 ratios are investigated. On the other hand, a parameter variation is used to achieve various particle temperatures during the process. The coatings are investigated via X-ray diffraction and DSC for phase formation, electron microscopy for coating structure and impedance spectroscopy for measuring the AC-resistance. The conducted variation of the feedstock material as well as the parameters causes differences in the XRD and DSC measurements correlating with a difference in the amounts of amorphous phases. For the capacitive behaviour, coatings applied with hydrogen as process gas showed decreased AC-resistance values. The chemical composition of the feedstock material indicates that the AC-resistance decreases with increasing amounts of SiO2. In summary, mullite has promising insulation properties which can be modified by the feedstock material composition as well as the coating parameters. For future application, mullite is a promising candidate for increasing the electrical insulation properties in conditions under high electrical and mechanical demands.

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