Abstract

This research is focused on the application of the Al2O3-phosphate ceramic coating on mild steel surface to protect mild steel from erosion in coal dust environment. Erosion resistance of mild steel could be improved by overlay it with SiC in the Al2O3-phosphate ceramic coating. As a filler, Al2O3 was mixed with 20%, 40%, and 60% SiC by using aluminum phosphate as a binder and heated at 220oC for 5 hours. X-ray diffraction testing was conducted to observe the phase of Al2O3-SiC phosphate ceramic coating. Meanwhile, surface morphology and adhesion characteristic of Al2O3-SiC phosphate ceramic coating was analyzed by scanning electron microscope. In order to analyse the erosion resistance quantitatively solid particle impingement test by applying gas jets at the right angle (90o) against a sample surface has been conducted. The results showed that Al2O3-SiC phosphate ceramic coating is strongly bonded on mild steel surface without the present of any void. The more SiC content the more its dense ceramic coating and erosion resistance. The SiC 60% produces four times erosion resistance higher than uncoated mild steel. The material characterization of Al2O3-SiC phosphate ceramic coating proves that SiC give significant impact on the enhancement of erosion resistance of the Al2O3-SiC phosphate ceramic coating.

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