Electrophoretic deposition (EPD) was employed to coat yttria-stabilised zirconia (YSZ) on Fecralloy. Various non-aqueous solvents were utilised to achieve smooth crack-free YSZ coatings. The EPD parameters, including solvent type, sedimentation height, zeta potential, particle size, pH and deposition weight, were studied. The micro-structural evolution and mechanical properties of the coatings were studied by the field emission scanning electron microscopy and micro-hardness, respectively. It was found that coatings obtained from 0.4 g L−1 I2 acetyl–acetone were uniform, smooth and crack free. Also they had narrow particle size distributions and higher zeta potential in the suspension. The experimental results revealed that suspension stability was a requirement for obtaining high-quality coatings and deposition yield for stable suspensions was higher; however, particle coagulation resulted in coatings with low green density and poor sinter ability. A transition in deposition mechanism from linear to parabolic was observed during EPD where deposition rate was decreased by time.
FauchaisP. L., HeberleinJ. V. R. and BoulosM. I., ‘Industrial applications of thermal spraying technology’, in ‘Thermal spray fundamentals’, (ed. P. L. Fauchais, J. V. R. Heberlein and M. I. Boulos), 1401–1566; 2013, New York, Springer.
PiaG., CasnediL. and SannaU.: ‘Porosity and pore size distribution influence on thermal conductivity of yttria-stabilized zirconia: experimental findings and model predictions’, Ceram. Int., 2016,
42, (5), 5802–5809. doi: 10.1016/j.ceramint.2015.12.122
5.
El HajjajiS., BachirA. Ben and AriesL.: ‘Electrolytic deposits on stainless steel as high temperature coatings’, Surf. Eng., 2001,
17, (3), 201–204. doi: 10.1179/026708401101517809
6.
RazaviM., FathiM., SavabiO., VashaeeD. and TayebiL.: ‘Biodegradable magnesium alloy coated by fluoridated hydroxyapatite using MAO/EPD technique’, Surf. Eng., 2014,
30, (8), 545–551. doi: 10.1179/1743294414Y.0000000284
7.
GhasemiR., Shoja-RazaviR., MozafariniaR., JamaliH., Hajizadeh-OghazM. and Ahmadi-PidaniR.: ‘The influence of laser treatment on hot corrosion behavior of plasma-sprayed nanostructured yttria stabilized zirconia thermal barrier coatings’, J. Eur. Ceram. Soc., 2014,
34, (8), 2013–2021. doi: 10.1016/j.jeurceramsoc.2014.01.031
8.
UchikoshiT., SuzukiT. S., OkuyamaH., SakkaY. and NicholsonP. S.: ‘Electrophoretic deposition of alumina suspension in a strong magnetic field’, J. Eur. Ceram. Soc., 2004,
24, (2), 225–229. doi: 10.1016/S0955-2219(03)00242-5
9.
CaubertF., TabernaP.-L. and AruraultL.: ‘Innovating pulsed electrophoretic deposition of boehmite nanoparticles dispersed in an aqueous solution, into a model porous anodic film, prepared on aluminium alloy 1050’, Surf. Coat. Technol., 2016,
302, 293–301. doi: 10.1016/j.surfcoat.2016.06.009
10.
MoritzK. and AnezirisC. G.: ‘Electrophoretic deposition of yttria-stabilised zirconia powder from aqueous suspensions for fabricating ceramics with channel-like pores’, J. Eur. Ceram. Soc., 2014,
34, (2), 401–412. doi: 10.1016/j.jeurceramsoc.2013.08.019
11.
SunY., AtaM. and ZhitomirskyI.: ‘Electrophoretic deposition of linear polyethylenimine and composite films’, Surf. Eng., 2013,
29, (7), 495–499. doi: 10.1179/1743294413Y.0000000156
12.
BesraL. and LiuM.: ‘A review on fundamentals and applications of electrophoretic deposition (EPD)’, Prog. Mater. Sci., 2007,
52, (1), 1–61. doi: 10.1016/j.pmatsci.2006.07.001
13.
XiaoX. F. and LiuR. F.: ‘Effect of suspension stability on electrophoretic deposition of hydroxyapatite coatings’, Mater. Lett., 2006,
60, (21), 2627–2632. doi: 10.1016/j.matlet.2006.01.048
14.
FengqiuT., XiaoxianH., YufengZ. and JingkunG.: ‘Effect of dispersants on surface chemical properties of nano-zirconia suspensions’, Ceram. Int., 2000,
26, (1), 93–97. doi: 10.1016/S0272-8842(99)00024-3
15.
ArunaS. and RajamK.: ‘A study on the electrophoretic deposition of 8YSZ coating using mixture of acetone and ethanol solvents’, Mater. Chem. Phys., 2008,
111, (1), 131–136. doi: 10.1016/j.matchemphys.2008.03.035
16.
BoccacciniA., ChoJ., SubhaniT., KayaC. and KayaF.: ‘Electrophoretic deposition of carbon nanotube–ceramic nanocomposites’, J. Eur. Ceram. Soc., 2010,
30, (5), 1115–1129. doi: 10.1016/j.jeurceramsoc.2009.03.016
17.
LiC., WangW., TanS. and SongS.: ‘Bond strength and oxidation resistance of YSZ/(Ni, Al) composite coatings’, Surf. Eng., 2014,
30, (9), 619–623. doi: 10.1179/1743294414Y.0000000295
18.
Farrokhi-RadM. and ShahrabiT.: ‘Effect of suspension medium on the electrophoretic deposition of hydroxyapatite nanoparticles and properties of obtained coatings’, Ceram. Int., 2014,
40, (2), 3031–3039. doi: 10.1016/j.ceramint.2013.10.004
19.
AnnéG., NeirinckB., VanmeenselK., BiestO. and VleugelsJ.: ‘Origin of the potential drop over the deposit during electrophoretic deposition,’ J. Am. Ceram. Soc., 2006,
89, (3), 823–828. doi: 10.1111/j.1551-2916.2005.00817.x
20.
FerrariB. and MorenoR.: ‘EPD kinetics: a review’, J. Eur. Ceram. Soc., 2010,
30, (5), 1069–1078. doi: 10.1016/j.jeurceramsoc.2009.08.022
21.
BiesheuvelP. M. and VerweijH.: ‘Theory of cast formation in electrophoretic deposition’, J. Am. Ceram. Soc., 1999,
82, (6), 1451–1455. doi: 10.1111/j.1151-2916.1999.tb01939.x
22.
KremserL., BlaasD. and KenndlerE.: ‘Capillary electrophoresis of biological particles: viruses, bacteria, and eukaryotic cells’, Electrophoresis, 2004,
25, (14), 2282–2291. doi: 10.1002/elps.200305868
23.
HamakerH.: ‘Formation of a deposit by electrophoresis’, Trans. Faraday Soc., 1940,
35, 279–287. doi: 10.1039/tf9403500279
24.
Sa'adatiH., RaissiB., RiahifarR. and YaghmaeeM. S.: ‘How preparation of suspensions affects the electrophoretic deposition phenomenon’, J. Eur. Ceram. Soc., 2016,
36, (2), 299–305. doi: 10.1016/j.jeurceramsoc.2015.09.005
25.
SarkarP. and NicholsonP. S.: ‘Electrophoretic deposition (EPD): mechanisms, kinetics, and application to ceramics’, J. Am. Ceram. Soc., 1996,
79, (8), 1987–2002. doi: 10.1111/j.1151-2916.1996.tb08929.x
26.
AnneG., VanmeenselK., VleugelsJ. and Van der BiestO.: ‘A mathematical description of the kinetics of the electrophoretic deposition process for Al2O3-based suspensions'’, J. Am. Ceram. Soc., 2005,
88, (8), 2036–2039. doi: 10.1111/j.1551-2916.2005.00387.x
27.
FerrariB., MorenoR. and CuestaJ. A.: ‘A resistivity model for electrophoretic deposition’, Key Eng. Mater., 2006,
314, 175–180. doi: 10.4028/www.scientific.net/KEM.314.175
28.
FarnoushH., MohandesiJ. A., FatmehsariD. H. and MoztarzadehF.: ‘A kinetic study on the electrophoretic deposition of hydroxyapatite–titania nanocomposite based on a statistical approach’, Ceram. Int., 2012,
38, (8), 6753–6767. doi: 10.1016/j.ceramint.2012.05.070
29.
CiouS.-J., FungK.-Z. and ChiangK.-W.: ‘The mathematical expression for kinetics of electrophoretic deposition and the effects of applied voltage’, J. Power Sour., 2007,
172, (1), 358–362. doi: 10.1016/j.jpowsour.2007.07.046
30.
GuoF. and XiaoP.: ‘Effect of Fe2O3 doping on sintering of yttria-stabilized zirconia’, J. Eur. Ceram. Soc., 2012,
32, (16), 4157–4164. doi: 10.1016/j.jeurceramsoc.2012.07.035
31.
BaiM., GuoF. and XiaoP.: ‘Fabrication of thick YSZ thermal barrier coatings using electrophoretic deposition’, Ceram. Int., 2014,
40, (10), 16611–16616. doi: 10.1016/j.ceramint.2014.08.021
32.
GuoF., JavedA. and XiaoP.: ‘Microstructure, oxidation behaviour and mechanical properties of Fe2O3 doped yttria-partially-stabilized zirconia coatings produced on metallic substrates by electrophoretic deposition’, Surf. Coat. Technol., 2015,
264, 17–22. doi: 10.1016/j.surfcoat.2015.01.033
33.
GarciaP., FerrariB., MorenoR., Sánchez-HerenciaA. J. and ColomerM. T.: ‘YSZ/ni–YSZ semi-cells shaped by electrophoretic deposition’, J. Eur. Ceram. Soc., 2007,
27, (13), 4241–4244. doi: 10.1016/j.jeurceramsoc.2007.02.142
34.
DasD. and BasuR. N.: ‘Suspension chemistry and electrophoretic deposition of zirconia electrolyte on conducting and non-conducting substrates’, Mater. Res. Bull., 2013,
48, (9), 3254–3261. doi: 10.1016/j.materresbull.2013.05.034
35.
KalininaE., EfimovA. and SafronovA.: ‘The influence of nanoparticle aggregation on formation of ZrO2 electrolyte thin films by electrophoretic deposition’, Thin Solid Films, 2016,
612, 66–71. doi: 10.1016/j.tsf.2016.05.039
36.
KouraN., TsukamotoT., HiromasaShojiT. and HottaT.: ‘Preparation of various oxide films by an electrophoretic deposition method: a study of the mechanism’, Jpn. J. Appl. Phys., 1995,
34, (3R), 1643–1444. doi: 10.1143/JJAP.34.1643
37.
Shri PrakashB., Senthil KumarS. and ArunaS.: ‘Properties and development of Ni/YSZ as an anode material in solid oxide fuel cell: A review’, Renew. Sustain. Energy Rev., 2014,
36, 149–179. doi: 10.1016/j.rser.2014.04.043
38.
BonnasS., Ritzhaupt-KleisslH.-J. and HaußeltJ.: ‘Fabrication of particle and composition gradients by systematic interaction of sedimentation and electrical field in electrophoretic deposition’, J. Eur. Ceram. Soc., 2010,
30, (5), 1177–1185. doi: 10.1016/j.jeurceramsoc.2009.08.007
39.
ZhangD., LiX., QinB., LiX., GuoX. and LaiC.: ‘Fabrication of chromium (III) oxide (Cr2O3) coating by electrophoretic deposition’, J. Am. Ceram. Soc., 2014,
97, (11), 3413–3417. doi: 10.1111/jace.13147
40.
FalkG., NoldA. and WiegandB.: ‘Experimental and numerical analysis of electrophoretic deposition on charge selective surfaces in external electric fields’, Adv. Appl. Ceram., 2014,
113, (1), 55–64. doi: 10.1179/1743676113Y.0000000129
41.
HasanpoorM., AliofkhazraeiM. and DelavariH.: ‘In-situ study of mass and current density for electrophoretic deposition of zinc oxide nanoparticles’, Ceram. Int., 2016,
42, (6), 6906–6913. doi: 10.1016/j.ceramint.2016.01.076
ParkJ. H. and ParkJ. M.: ‘Electrophoretic deposition of graphene oxide on mild carbon steel for anti-corrosion application’, Surf. Coat. Technol., 2014,
254, 167–174. doi: 10.1016/j.surfcoat.2014.06.007
DasD. and BasuR. N.: ‘Electrophoretic deposition of thin film zirconia electrolyte on non-conducting NiO-YSZ substrate’, Trans. Indian Ceram. Soc., 2014,
73, (2), 90–93. doi: 10.1080/0371750X.2014.922701
46.
DrdlikD., BartonickovaE., HadrabaH. and CihlarJ.: ‘Influence of anionic stabilization of alumina particles in 2-propanol medium on the electrophoretic deposition and mechanical properties of deposits’, J. Eur. Ceram. Soc., 2014,
34, (14), 3365–3371. doi: 10.1016/j.jeurceramsoc.2014.04.038
47.
ZehbeR., MochalesC., RadzikD., MüllerW.-D. and FleckC.: ‘Electrophoretic deposition of multilayered (cubic and tetragonal stabilized) zirconia ceramics for adapted crack deflection’, J. Eur. Ceram. Soc., 2016,
36, (2), 357–364. doi: 10.1016/j.jeurceramsoc.2015.08.022
