Aluminum phosphate sealing to improve insulation resistance of plasma-sprayed alumina coating

The insulation resistance of conventional atmospheric plasma-sprayed alumina coatings with 10–15% porosity is ∼1011 Ω. The presence of pores, lamellae boundaries, and other non-fillings dampens the insulation resistance of the coating. In the present study, aluminum phosphate was used to seal the surface of plasma-sprayed alumina coating and evaluate the effect of sealing on the insulation resistance and its thermal cycling response. Sealing was carried out with three concentrations of sealant (P/Al molar ratio of 3, 10, and 15). Characterization by X-ray diffraction and scanning electron microscopy revealed the primary sealing phase as aluminum metaphosphate and effective sealing of the pores by the aluminum phosphate phases. Insulation resistance is improved by two orders of magnitude after sealing the coated samples. Sealing with P/Al molar ratio 3 exhibited maximum insulation resistance of ∼1013 Ω at room temperature. Thermal cycling studies between 650°C and 200°C on the sealed samples showed deterioration in thermal cycling life after sealing.